Sheet/Panel Design for Enclosure Component Manufacture

ABSTRACT

An enclosure component for a building having first and second adjacent metal sheets, with an insertion section on an interior edge of the second metal sheet positioned within a receiver section of an interior edge of the first metal sheet, the first and second metal sheets being bonded to a planar foam panel layer with an edge portion of an exterior edge of the first metal sheet received in a locating slot of an edge seal positioned on the edge of the foam panel layer.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/136,268 filed Jan. 12, 2021, U.S. Provisional Application No. 63/181,447, filed Apr. 29, 2021, and U.S. Provisional Application No. 63/196,400 filed Jun. 3, 2021.

BACKGROUND OF THE INVENTION Field of the Invention

The inventions herein relate to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and to components for such structures.

Description of the Related Art

In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.

There have been a variety of efforts to depart from the conventional construction techniques used to create dwellings, as well as commercial spaces and like. One of the alternatives to stick-built construction is very generally referred to as modular housing. As opposed to stick-built construction, where the structure is built on-site, a modular house is constructed in a factory and then shipped to the site, often by means of a tractor-trailer.

Such modular housing often exceeds in size normally-permitted legal limits for road transport. For example, in the United States the maximum permitted dimensions for road transport are in general 102 inches (259.1 cm) in width, 13.5 feet (4.11 m) in height and 65 to 75 feet (19.81 to 22.86 m) in length. Thus, in many cases transporting a modular house from factory to site requires oversize load permits, which may impose restrictions on when transport can be undertaken and what routes can be utilized. Oversize road regulations may also require the use of an escort car and a trailing car as well. All of these requirements and restrictions inevitably increase the cost of the modular housing.

Significant advancements in the construction of dwellings and commercial space are described in U.S. Pat. Nos. 8,474,194, 8,733,029, 10,688,906, 10,829,029 and 10,926,689. In one aspect, these patents pertain to fabricating wall, floor and roof components in a factory that are folded together into a compact shipping module, and which are then transported to the intended location and unfolded to yield a fully formed structure.

SUMMARY OF THE INVENTION

The present inventions describe advancements in the design of components for the manufacture of foldable, transportable building structures.

In a first aspect, the present inventions are directed to an enclosure component for a building structure comprising a first structural layer including a rectangular first metal sheet having an interior sheet face, an exterior sheet face and a first exterior sheet edge having an elongate edge portion bent to extend away from the interior sheet face. There is provided a planar foam panel layer having a first face, an opposed second face and a first exterior panel edge, with the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet. There is additionally provided a planar elongate first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, with the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer. The first edge seal includes an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.

In a second aspect, the present inventions are directed to an enclosure component for a building structure comprising a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet, with the first metal sheet having an interior sheet face, a first exterior sheet edge and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior sheet edge of the first metal sheet. The first interior sheet edge of the first metal sheet includes a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet. The second interior edge of the second metal sheet includes an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the first metal sheet. The insertion section of the second metal sheet is positioned within the receiver section of the second metal sheet, and the first exterior edge of the first metal sheet includes an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet. There is also provided a planar foam panel layer having a first face, an opposed second face, and an exterior panel edge, with the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, and with the first face of the foam panel layer defining a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section. There is additionally provided a first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, with the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer, and the first edge seal including an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.

In a third aspect, the present inventions are directed to an enclosure component for a building structure comprising a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet, with the first metal sheet having an interior sheet face and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior edge of the first metal sheet. The first interior sheet edge of the first metal sheet includes a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet, with a portion of the planar elongate second receiver region closest to the interior sheet face of the first metal sheet terminating at a free edge distal from the first receiver bend. The second interior edge of the second metal sheet includes an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the second metal sheet, with a portion of the planar elongate second insertion region closest to the interior sheet face of the second metal sheet terminating at a free edge distal from the first insertion bend. The insertion section of the second metal sheet is positioned within the receiver section of the first metal sheet, and there is provided a planar foam panel layer having a first face and an opposed second face, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, with the first face of the foam panel layer including a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section.

These and other aspects of the present inventions are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a structure prepared in accordance with the present inventions.

FIG. 2 is a top schematic view of the structure shown in FIG. 1.

FIG. 3 is an end view of a shipping module from which is formed the structure shown in FIG. 1.

FIGS. 4 and 5 are partial cutaway views of a structure in accordance with the present inventions, depicting in greater detail aspects of the roof, wall and floor components.

FIG. 6 is a schematic perspective view depicting the exterior edge reinforcement for a wall component in accordance with the present inventions.

FIG. 7 is an exploded cross-sectional view of a multi-layered, laminate design for use in the enclosure components of the present inventions.

FIG. 8 is an exploded perspective view of the metal sheets of the sheet metal layer forming a first structural layer in accordance with the present inventions.

FIG. 9A is a side view of an exterior edge structure in accordance with the present inventions, FIG. 9B is a first embodiment of an interior edge interface in accordance with the present inventions, and FIG. 9C is a second embodiment of an interior edge interface in accordance with the present inventions.

FIG. 10 is a schematic side view of an I-beam end cap in accordance with the present inventions.

FIG. 11A is a section view of a compression seal in accordance with the present inventions, and FIG. 11B is a side view of a roof bottom plate with a compression seal provided in one of its two seal slots in accordance with the present inventions.

FIG. 12 is an exploded side view of the junction between a wall vertical interlock and a wall end cap in accordance with the present inventions, and FIG. 13 is an exploded side view of the junction between a roof bottom plate and wall end cap in accordance with the present inventions.

FIG. 14 is an exploded side view of the junction between an I-beam interlock A and an I-beam interlock B in accordance with the present inventions.

FIG. 15 is an exploded side view of the junction between a floor top plate and a wall end cap in accordance with the present inventions.

FIG. 16A is a section view of a shear seal in accordance with the present inventions, and FIG. 16B is a side view of a wall end interlock with a shear seal provided in its seal slot in accordance with the present inventions.

FIG. 17 is an exploded side view of the junction between a floor top interlock and a wall end interlock A in accordance with the present inventions.

FIG. 18 is an exploded side view of the junction between a wall end interlock B and a wall end interlock A in accordance with the present inventions.

FIG. 19A is a side view of the junction between a perimeter board and an I-beam end lock in accordance with the present inventions, and FIG. 19B is a depiction of the positioning of an I-beam end cap, a floor top plate, a wall end cap and a perimeter board in accordance with the present inventions.

FIG. 20 is a side view of the junction between a roof skirt board and an I-beam end lock in accordance with the present inventions.

FIG. 21A is an exploded perspective view of a finished structure in accordance with the present inventions, depicting suitable locations for the sealing systems of the present inventions on the horizontally positioned enclosure components, and FIG. 21B is an exploded perspective view of a finished structure in accordance with the present inventions, depicting correspondingly suitable locations for the sealing systems of the present inventions on the vertically positioned enclosure components.

FIG. 22 is a perspective view of an enclosure component fabrication facility in accordance with the present inventions.

FIGS. 23A-23J are depictions at different times of the fabrication of an exemplary wall component utilizing the enclosure component fabrication facility shown in FIG. 22 in accordance with the present inventions.

FIG. 24A is a side view of a roof portion depicting in part metal sheet edge portions received in locating slots in accordance with the present invention, and FIG. 24B is a schematic side view of an embodiment of an interior edge interface received in a foam panel channel in accordance with the present inventions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1 through 5. When fully unfolded, as exemplified by FIG. 1, structure 150 has a rectangular shape made of three types of generally planar and rectangular enclosure components 155, the three types of enclosure components 155 consisting of a wall component 200, a floor component 300, and a roof component 400. As shown in FIGS. 1 and 2, the perimeter of structure 150 is defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge 116 and second transverse edge 110. For convenience, a direction parallel to first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction, a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction; and a direction parallel to the vertical direction in FIG. 1 may be referred to as the “vertical” direction. Structure 150 as shown has one floor component 300, one roof component 400 and four wall components 200; although it should be understood that the present inventions are applicable to structures having other configurations as well.

Enclosure components 155 (wall component 200, floor component 300 and roof component 400) can be fabricated and dimensioned as described herein and positioned together to form a shipping module 100, shown end-on in FIG. 3. The enclosure components 155 are dimensioned so that the shipping module 100 is within U.S. federal highway dimensional restrictions. As a result, shipping module 100 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize permits. Thus, the basic components of structure 150 can be manufactured in a factory, positioned together to form the shipping module 100, and the modules 100 can be transported to the desired site for the structure, where they can be readily assembled, as described herein.

Enclosure Component (155): General Description

The enclosure components 155 of the present invention include a number of shared design features that are described below.

A. Laminate Structure Design

Enclosure components 155 can be fabricated using a multi-layered, laminate design. A particular laminate design that can be used to fabricate enclosure components 155 comprises a first structural layer 210, a foam panel layer 213, a second structural layer 215 and a protective layer 218, as shown in FIG. 7 and described further below.

In particular, first structural layer 210 is provided in the embodiment of enclosure component 155 that is depicted in FIG. 7. First structural layer 210 in the embodiment shown comprises a sheet metal layer 205, which can be for example galvanized steel or aluminum. Sheet metal layer 205 is made from a plurality of generally planar rectangular metal sheets 206 positioned adjacent to each other to generally cover the full area of the intended enclosure component 155.

Referring again to FIG. 7, there is next provided in the depicted embodiment of enclosure component 155 a foam panel layer 213, comprising a plurality of generally planar rectangular foam panels 214 collectively presenting a first face 211 and a second opposing face 212. Foam panels 214 are made for example of expanded polystyrene (EPS) foam. A number of these foam panels 214 are positioned adjacent to each other and superposed first face-down on first structural layer 210 to generally cover the full area of the intended enclosure component 155. The foam panels 214 of foam panel layer 213 preferably are fastened to first structural layer 210 using a suitable adhesive, preferably a polyurethane based construction adhesive. Foam panel layer 213 can include exterior edge reinforcement and interior edge reinforcement, as described further below.

In the embodiment of the enclosure component 155 depicted in FIG. 7, there is next provided a second structural layer 215, having a first face that is positioned on the second opposing face 212 of foam panels 214 (the face distal from first structural layer 210), and also having a second opposing face. Second structural layer 215 in the embodiment shown comprises a sheet metal layer 216, which can be for example galvanized steel or aluminum. Sheet metal layer 216 is made from a plurality of generally planar rectangular metal sheets 217 positioned adjacent to each other and superposed first face-down on the second opposing face of foam panel layer 213 to generally cover the full area of the intended enclosure component 155. The metal sheets 217 of second structural layer 215 preferably are fastened to foam panel layer 213 using a suitable adhesive, preferably a polyurethane based construction adhesive.

In the embodiment of the enclosure component 155 depicted in FIG. 7, there is optionally next provided a protective layer 218, having a first face that is positioned on the second opposing face of second structural layer 215 (the face distal from foam panel layer 213), and also having a second opposing face. Optional protective layer 218 in the embodiment shown comprises a plurality of rectangular structural building panels 219 principally comprising an inorganic composition of relatively high strength, such as magnesium oxide (MgO). The structural building panels 219 are positioned adjacent to each other and superposed first face-down on the second opposing face of second structural layer 215 to generally cover the full area of the intended enclosure component 155. The building panels 219 of protective layer 218 preferably are fastened to second structural layer 215 using a suitable adhesive, preferably a polyurethane based construction adhesive. Protective layer 218 can be used if desired to impart a degree of fire resistance to the enclosure component 155, as well as to provide a pleasing texture and/or feel.

Other embodiments of multi-layered, laminate designs, which can be used to fabricate the enclosure components 155 of the present invention, are described in U.S. Nonprovisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on Feb. 10, 2020, which has issued as U.S. Pat. No. 11,118,344. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on Feb. 10, 2020 are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶ 0034-57 and depicted in FIGS. 4A-4D thereof.

B. Enclosure Component Exterior Edge Reinforcement

The exterior edges of each enclosure component 155 (i.e., the edges that define the perimeter of enclosure component 155) can be provided with exterior edge reinforcement, as desired. Exterior edge reinforcement generally comprises an elongate, rigid member which can protect the foam panel material of foam panel layer 213 that would otherwise be exposed at the exterior edges of enclosure components 155. Exterior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the exterior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

C. Enclosure Component Partitioning

Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 100. In those instances where an enclosure component 155 is partitioned into enclosure component portions, any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions.

The enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a compact shipping module 100.

D. Enclosure Component Interior Edge Reinforcement

An enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect the foam panel material of foam panel layer 213 which would otherwise be exposed at the interior edges of enclosure components 155. Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

E. Enclosure Component Load Transfer

In the case of enclosure components 155, it is necessary to transfer the loads imposed on their surfaces to their exterior edges, where those loads can be transferred either to or through adjoining walls, or to the building foundation. For enclosure components 155 that are horizontally oriented when in use (floor component 300 and roof component 400), such loads include the weight of equipment, furniture and people borne by their surfaces, as well as vertical seismic loads. For enclosure components that are vertically oriented when in use (wall component 200), such loads include those arising from meteorological conditions (hurricanes, tornadoes, etc.) and human action (vehicle and other object impacts).

For this purpose, multi-layered, laminate designs as shown in FIG. 7 will function to transfer the loads described above. To add additional load transfer capability, structural members, such as beams and/or joists, can be utilized within the perimeter of the enclosure components 155, as is deemed appropriate to the specific design of structure 150 and the particular enclosure component 155, to assist in the transfer of loads to the exterior edges. Particular embodiments of such structural members, which also incorporate hinge structures, are described in U.S. Provisional Patent Application No. 63/188,101, filed May 13, 2021, entitled “Folding Beam Systems” and having the same inventors as this disclosure.

Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following.

Wall Component (200)

Typically, structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.

A. General Description

Wall component 200 has a generally rectangular perimeter. As shown in FIG. 1, wall components 200 have plural apertures, specifically a door aperture 202, which has a door frame and door assembly, and plural window apertures 204, each of which has a window frame and a window assembly. The height and length of wall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above. In this disclosure, structure 150 is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116, and its first and second transverse edges 108 and 110, are all of equal length. It should be understood however, that the inventions described herein are applicable to structures having other dimensions, such as where two opposing wall components 200 are longer than the other two opposing wall components 200.

As indicated above, wall components 200 of the present inventions can utilize a multi-layered, laminate design. In the embodiment depicted in FIGS. 1 through 6, wall component 200 utilizes the multi-layered, laminate design shown in FIG. 7 employing these particular elements: sheet metal layer 205 of first structural layer 210 is 24 gauge galvanized steel approximately 0.022-0.028 inch thick, the foam panels 214 of foam panel layer 213 are EPS foam approximately 5.68 inches thick, the sheet metal layer 216 of second structural layer 215 is 24 gauge galvanized steel approximately 0.022-0.028 inch thick, and the building panels 219 of protective layer 218 are MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of each wall component 200 is generally provided with exterior edge reinforcement. As exemplified by wall component 200 shown in FIG. 6, the exterior edge reinforcement for wall component 200 is a floor plate 220 along the bottom horizontal edge, a ceiling plate 240 along the top horizontal edge and two end pieces 270 respectively fastened at each vertical edge of wall component 200. In the case of a wall component 200, exterior edge reinforcement provides regions for fastening like regions of abutting wall components 200, roof component 400 and floor component 300, in addition to protecting the exterior edges of foam panel material.

In the embodiment shown in FIGS. 1 through 6, the exterior edge reinforcement for wall component 200 provided by floor plate 220, ceiling plate 240, and end pieces 270 is fabricated from laminated strand lumber board 5.625″ deep and 1.5″ thick.

B. Partitioned Wall Components

Referring to FIG. 2, structure 150 has two opposing wall components 200, where one of the two opposing wall components 200 comprises first wall portion 200 s-1 and second wall portion 200 s-2, and the other of the two opposing wall components 200 comprises third wall portion 200 s-3 and fourth wall portion 200 s-4. Each of wall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 has a generally rectangular planar structure. As shown in FIG. 2, the interior vertical edge 192-1 of wall portion 200 s-1 is proximate to a respective interior vertical edge 192-2 of wall portion 200 s-2, and the interior vertical edge 194-3 of wall portion 200 s-3 is proximate a respective interior vertical wall edge 194-4 of wall portion 200 s-4. Interior edge reinforcement can be provided at any one or more of vertical edges 192-1, 192-2, 194-3 and 194-4. In the embodiment shown in FIGS. 1 through 6, the interior edge reinforcement provided at vertical edges 192-1, 192-2, 194-3 and 194-4 is fabricated from laminated strand lumber board 5.625″ deep and 1.5″ thick.

Referring again to FIG. 2, first wall portion 200 s-1 is fixed in position on floor portion 300 a proximate to first transverse edge 108, and third wall portion 200 s-3 is fixed in position on floor portion 300 a, opposite first wall portion 200 s-1 and proximate to second transverse edge 110. First wall portion 200 s-1 is joined to second wall portion 200 s-2 with a hinge structure that permits wall portion 200 s-2 to pivot about vertical axis 192 between a folded position and an unfolded position, and third wall portion 200 s-3 is joined to fourth wall portion 200 s-4 with a hinge structure to permit fourth wall portion 200 s-4 to pivot about vertical axis 194 between a folded position and an unfolded position.

Notably, first wall portion 200 s-1 is longer than third wall portion 200 s-3 by a distance approximately equal to the thickness of wall component 200, and second wall portion 200 s-2 is shorter than third wall portion 200 s-3 by a distance approximately equal to the thickness of wall component 200. Furthermore, wall portion 200 s-1 and wall portion 200 s-3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300 a in the transverse direction. Dimensioning the lengths of wall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 in this manner permits wall portions 200 s-2 and 200 s-4 to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard, FIG. 2 depicts wall portions 200 s-2 and 200 s-4 both in their unfolded positions, where they are labelled 200 s-2 u and 200 s 4-u respectively, and FIG. 2 also depicts wall portions 200 s-2 and 200 s-4 both in their inwardly folded positions, where they are labelled 200 s-2 f and 200 s 4-f respectively. When wall portions 200 s-2 and 200 s-4 are in their inwardly folded positions (200 s-2 f and 200 s-4 f), they facilitate forming a compact shipping module. When wall portion 200 s-2 is in its unfolded position (200 s-2 u), it forms with wall portion 200 s-1 a wall component 200 proximate first transverse edge 108, and when wall portion 200 s-4 is in its unfolded position (200 s-4 u), it forms with wall portion 200 s-3 a wall component 200 proximate second transverse edge 110.

The hinge structures referenced for securing first wall portion 200 s-1 to second wall portion 200 s-2, and third wall portion 200 s-3 to fourth wall portion 200 s-4, can be surface mounted or recessed, and of a temporary or permanent nature. The provision of interior edge reinforcement, as described above, can provide a region for securing such hinge structures. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.

C. Unpartitioned Wall Components

As compared to the two wall components 200 proximate first and second transverse edges 108 and 110, which are partitioned into wall portions, the remaining two wall components 200 proximate first and second longitudinal edges 106 and 116 do not comprise plural wall portions, but rather each is a single piece structure. However, one of these wall components 200, which is sometimes denominated 200P in this disclosure, and which is located on floor portion 300 b proximate first longitudinal edge 106, is pivotally secured to floor portion 300 b by means of hinge structures to permit wall component 200P to pivot about horizontal axis 105 shown in FIG. 3 from a folded position to an unfolded position. Pivotally securing wall component 200P also facilitates forming a compact shipping module 100. The remaining wall component 200, sometimes denominated 200R in this disclosure, is rigidly secured on floor portion 300 a proximate second longitudinal edge 116 and abutting the vertical edges of first wall portion 200 s-1 and third wall portion 200 s-3 proximate to second longitudinal edge 116, as shown in FIG. 2.

The hinge structures described above, for securing wall component 200P to floor portion 300 b, can be surface mounted or recessed, and of a temporary or permanent nature. The provision of exterior edge reinforcement, as described above, can provide a region for securing such hinge structures. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material.

Floor Component (300)

Typically, structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.

A. General Description

Floor component 300 has a generally rectangular perimeter. FIGS. 4 and 5 depict floor component 300 in accordance with the present inventions. The perimeter of floor component 300 is defined by first longitudinal floor edge 117, first transverse floor edge 120, second longitudinal floor edge 119 and second transverse floor edge 118. In particular, (a) first longitudinal floor edge 117, (b) first transverse floor edge 120, (c) second longitudinal floor edge 119 and (d) second transverse floor edge 118 generally coincide with (i.e., underlie) (w) first longitudinal edge 106, (x) first transverse edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110, respectively, of structure 150.

The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 2, 4 and 5, floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component 300 may be subject. It is preferred that floor component 300 utilize a multi-layered, laminate design, such as that described in connection with FIG. 7. In the embodiment shown in FIGS. 4 and 5, the bottom-most surface of floor component 300 comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205 being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer 205 there are provided foam panels 214 of foam panel layer 213. In the embodiment shown in FIGS. 4 and 5, foam panels 214 are EPS foam approximately 7.125 inches thick. Above foam panel layer 213 there is provided sheet metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Above sheet metal layer 216 of second structural layer 215, there are provided building panels 219 of protective layer 218, with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of each floor component 300 is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiments of floor component 300 shown in FIGS. 4 and 5, a first footing beam 320 (visible edge-on in FIG. 4) is positioned at the first longitudinal floor edge 117 of floor component 300, a second footing beam 320 (visible edge-on in FIG. 5) is positioned at the second transverse floor edge 118 of floor component 300, a third footing beam 320 (visible edge-on in FIG. 5) is positioned at the first transverse floor edge 120 of floor component 300, and a fourth footing beam 320 (visible edge-on in FIG. 4) is positioned at the second longitudinal floor edge 119 of floor component 300. In the case of floor component 300, the exterior edge reinforcement provided by footing beams 320 assists in resisting vertical loads and transferring such loads to any roof component 400 thereunder and then to underlying wall components 200, and/or to the foundation of the structure 150, in addition to protecting the edges of foam panel material of the foam panel layer 213.

In the embodiment shown in FIGS. 1 through 6, the exterior edge reinforcement provided by footing beams 420 of floor component 300 is fabricated from laminated strand lumber board 7.125″ deep and 1.5″ thick.

B. Floor Partitioning

The floor component 300 is partitioned into floor portion 300 a and floor portion 300 b. FIG. 2 shows flow portions 300 a and 300 b in plan view, and FIG. 4 shows floor portions 300 a and 300 b in section view, edge-on.

Each of the floor portions 300 a and 300 b is a planar generally rectangular structure, with floor portion 300 a adjoining floor portion 300 b. Interior edge 301 a of floor portion 300 a abuts interior edge 301 b of floor portion 300 b, as shown in FIG. 4. As interior edge reinforcement, a reinforcing board 307 is positioned in floor portion 300 a adjacent interior edge 301 a, and a reinforcing board is positioned in floor portion 300 b adjacent interior edge 301 b. Additional structural members, such as beam and/or joists, can be utilized within the perimeter of one or more of floor portions 300 a and 300 b, as is deemed appropriate to the specific design of structure 150 and floor component 300, to assist in the transfer of vertical loads to one or more of reinforcing boards 307.

Referring to structure 150 shown in FIGS. 2 and 4, floor portion 300 a is fixed in position relative to first wall portion 200 s-1, third wall portion 200 s-3 and wall component 200 s-R. Floor portion 300 a is joined with hinge structures to floor portion 300 b, so as to permit floor portion 300 b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305, located proximate the top surface of floor component 300, between a fully folded position, where floor portion 300 b is vertically oriented as shown in FIG. 3, and the fully unfolded position shown in FIGS. 2 and 4, where floor portion 300 b is horizontally oriented and co-planar with floor portion 300 a.

The hinge structures joining floor portions 300 a and 300 b can be surface mounted or recessed, and of a temporary or permanent nature. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material. The hinge structures joining floor portions 300 a and 300 b are adapted to pivot through approximately ninety degrees (90°) of arc.

There is provided interior edge reinforcement, reinforcing board 307, at each of interior edges 301 a and 301 b, as shown in FIG. 4. The interior edge reinforcement provided by reinforcing board 307 at interior edges 301 a, 301 b can provide a region for mounting hinge structures, in addition to protecting the edges of foam panel material. Reinforcing boards 307 can be made of laminated strand lumber laminated strand lumber board 7.125″ deep and 1.5″ thick.

Roof Component (400)

Typically, structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.

A. General Description

Roof component 400 has a generally rectangular perimeter. FIGS. 1, 4 and 5 depict roof component 400 in accordance with the present inventions. The perimeter of roof component 400 is defined by first longitudinal roof edge 406, first transverse roof edge 408, second longitudinal roof edge 416 and second transverse roof edge 410. In particular, (a) first longitudinal roof edge 406, (b) first transverse roof edge 408, (c) second longitudinal roof edge 416 and (d) second transverse roof edge 410 of roof component 400 generally coincide with (i.e., overlie) (w) first longitudinal edge 106, (x) first transverse edge 108, (y) second longitudinal edge 116 and (z) second transverse edge 110, respectively, of structure 150.

The length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1, 4 and 5, the length and width of roof component 400 approximates the length and width of floor component 300.

Roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component 400 may be subject. It is preferred that roof component 400 utilize a multi-layered, laminate design, such as that described in connection with FIG. 7. In the embodiment shown in FIGS. 4 and 5, the top-most surface of roof component 400 comprises sheet metal layer 205 of first structural layer 210, with sheet metal layer 205 being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Below sheet metal layer 205 there are provided foam panels 214 of foam panel layer 213, with foam panels 214 in the embodiment shown in FIGS. 4 and 5 being EPS foam approximately 7.125 inches thick. Below foam panel layer 213 there is provided sheet metal layer 216 of second structural layer 215, with sheet metal layer 216 being 24 gauge galvanized steel approximately 0.022-0.028 inch thick. Below sheet metal layer 216 of second structural layer 215, there are provided building panels 219 of protective layer 218, with building panels 219 being MgO board approximately 0.25 inch (6 mm) thick.

The perimeter of roof component 400 is generally provided with exterior edge reinforcement. As exterior edge reinforcement for the embodiment of roof component 400 shown in FIGS. 4 and 5, a first shoulder beam 435 (visible edge-on in FIG. 4) is positioned at the first longitudinal roof edge 406 of roof component 400, a second shoulder beam 435 (visible edge-on in FIG. 5) is positioned at the first transverse roof edge 408 of roof component 400, a third shoulder beam 435 (visible edge-on in FIG. 5) is positioned at the second transverse roof edge 410 of roof component 400, and a fourth shoulder beam 435 (visible edge-on in FIG. 4) is positioned at the second longitudinal roof edge 416 of roof component 400. In addition to protecting the exterior edges of foam panel material, the exterior edge reinforcement provided by shoulder beams 435 assists in resisting vertical loads and transferring such loads to lower floors through underlying wall components 200 supporting roof component 400, and then to the foundation of the structure 150. Such exterior edge reinforcement can also provide a region for fastening like regions of abutting enclosure components 155 (underlying and any overlying). Shoulder beams 435 of roof component 400 can be fabricated from laminated strand lumber board 7.125″ deep and 1.5″ thick.

B. Roof Partitioning

The roof component 400 of structure 150 is partitioned into roof portions 400 a, 400 b and 400 c. FIG. 1 shows roof portions 400 a, 400 b and 400 c in perspective view, and FIG. 4 shows roof portions 400 a, 400 b and 400 c in section view, edge-on.

Each of the roof portions 400 a, 400 b and 400 c is a planar generally rectangular structure, with roof portion 400 a adjoining roof portion 400 b, and roof portion 400 b adjoining roof portion 400 c. Interior edge 412 c of roof component 400 c abuts a first interior edge 412 b of roof component 400 b, as shown in FIG. 4. For interior edge reinforcement, a reinforcing board 437 is positioned adjacent interior edge 412 c, and a reinforcing board 437 is positioned against first interior edge 412 b. Interior edge 412 a of roof portion 400 a abuts a second interior edge 412 b of roof portion 400 b, as shown in FIG. 4. For interior edge reinforcement, a reinforcing board 437 is positioned adjacent interior edge 412 a, and a reinforcing board 437 is positioned against second interior edge 412 b. Additional structural members, such as beams and/or joists, can be utilized within the perimeter of one or more of roof portions 400 a, 400 b and 400 c, as is deemed appropriate to the specific design of structure 150 and roof component 400, to assist in the transfer of vertical loads to one or more shoulder beams 435.

Referring to structure 150 shown in FIG. 4, roof portion 400 a is fixed in position relative to first wall portion 200 s-1, third wall portion 200 s-3 and wall component 200R. Roof portion 400 a is joined to roof portion 400 b with hinge structures provided between interior edge 412 a of roof portion 400 a and second interior edge 412 b of roof portion 400 b. Such hinge structures are adapted to permit roof portion 400 b to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 a, located proximate the top of roof component 400 and shown in FIG. 4, between the fully folded position shown in FIG. 3, where roof portion 400 b lies flat against roof portion 400 a, and the fully unfolded position shown in FIG. 4.

In turn, roof portion 400 b is joined to roof portion 400 c with hinge structures provided between first interior edge 412 b of roof portion 400 b and interior edge 412 c of roof portion 400 c. Such hinge structures are adapted to permit roof portion 400 c to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 b, located proximate the bottom of roof component 400 and shown in FIG. 4, between the folded position shown in FIG. 3, where roof portion 400 c lies flat against roof portion 400 b (when roof portion 400 b is positioned to lie flat against roof portion 400 a), and the fully unfolded position shown in FIG. 4.

The hinge structures joining roof portions 400 a, 400 b and 400 c can be surface mounted or recessed, and of a temporary or permanent nature. Suitable hinge structures can be fabricated for example of ferrous or non-ferrous metal, plastic or leather material. The interior edge reinforcement provided by reinforcing boards 437 of roof portions 400 a, 400 b and 400 c can provide a region for mounting hinge structures, in addition to protecting the edges of foam panel material. Reinforcing boards 437 can be fabricated from laminated strand lumber board 7.125″ deep and 1.5″ thick.

Enclosure Component Sealing Systems

Structure 150 can utilize the enclosure component sealing systems described below to limit or prevent the ingress of rain water, noise and outside air into the interior of structure 150.

A. General Description

The enclosure component sealing systems for structure 150 utilize the sealing structures described below. Except for I-beam end cap 221, which functions to seal the edges of select enclosure components 155, the enclosure component sealing systems comprise in general terms two enclosure component sealing structures, paired in in pressing contact in different combinations, to seal the junctions between different regions of the enclosure components 155 found in structure 150. These junctions consist of either two interior edges of adjacent enclosure component portions, positioned edge-to-edge when structure 150 is unfolded, or an exterior edge of an enclosure component 155 which abuts an interior surface of another enclosure component 155. Where an enclosure component sealing structure is positioned on an interior or exterior edge of an enclosure component 155, there can respectively be provided interior edge reinforcement or exterior edge reinforcement between the sealing structure and the respective interior or exterior edge of the foam panel layer 213 in the case where the multi-layered, laminate design depicted in FIG. 7 is utilized (such that the enclosure component sealing structure is positioned proximate to the interior or exterior edge, as the case may be, of the foam panel layer 213). The specific enclosure component sealing structures described below are I-beam end cap 221; wall vertical interlock 245; wall end cap 246; I-beam interlock A 250; I-beam interlock B 251; floor top plate 252; roof bottom plate 255; floor top interlock 261; wall end interlock A 262; and wall end interlock B 263. Excepting I-beam end cap 221, each of the foregoing enclosure component sealing structures utilizes either two or more compression seals 230, or one shear seal 260, which are also described below.

The current inventions include two closure boards, namely perimeter board 310 and roof skirt board 280. These closure boards, which are described below, are utilized in conjunction with I-beam end cap 221 to provide additional sealing, as well as to realize additional benefits.

B. I-Beam End Cap (221)

I-beam end cap 221, shown in cross-section in FIG. 10, is a rigid elongate member that is fastened to the periphery of select enclosure components 155, preferably the exterior edges of floor component 300 and roof component 400. I-beam end cap 221 constitutes an edge seal that performs a sealing function against water ingress into and environmental exposure of the edge of the enclosure component 155 to which it is secured, and imparts impact resistance to that edge.

FIG. 10 shows an exemplary installation of I-beam end cap 221 secured to the edge of a schematic representation of floor portion 300 a. In particular, I-beam end cap 221 has an elongate seal plate 223 with seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227. I-beam end cap 221 has a length and width the same, or substantially the same, as the length and width of the exterior edge of floor portion 300 a, so as to cover the entirety, or substantially the entirety, of the exterior edge of floor portion 300 a.

At the mid-point of the interior face 226 of seal plate 223, there is provided an elongate key 222, which is rectangular in cross section (as shown in FIG. 10), and has a length the same, or substantially the same, as the length of I-beam end cap 221. Key 222 is received in a corresponding slot formed in the exterior edge reinforcement positioned on the exterior edge of the enclosure component 155 to which I-beam end cap 221 is secured. Thus for example, FIG. 24A depicts key 222 of an I-beam end cap 221 received in slot 422 of a shoulder beam 435 of roof portion 400 a. Each of the top and bottom edges of I-beam end cap 221 define locating slots 229. In the case where the enclosure component 155 utilizes the enclosure component laminate design shown in FIG. 7, locating slots 229 receive the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.

Still referring to FIG. 10, the exterior face 227 of seal plate 223 of I-beam end cap 221 includes an elongate accessory slot 224, which is rectangular in cross section and has a length the same, or substantially the same, as the length of the exterior face 227 of I-beam end cap 221. The exterior face 227 further includes a plurality of elongate fastener locating grooves 225, each of which has a length the same, or substantially the same, as the length of seal plate 223. I-beam end cap 221 can be secured to an exterior edge of an enclosure component 155, such as the floor portion 300 a shown in FIG. 10 and the roof portion 400 a shown in FIG. 24A, for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam end cap 221 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners. Locating grooves 225 assist in accurate positioning of such fasteners.

C. Compression Seal (230)

A number of the enclosure component sealing systems described herein and utilized in structure 150 include a compression seal system. An element of that compression seal system is a compression seal 230.

Compression seal 230, which is shown in cross-section in FIG. 11A, is an elongate member having in cross-section an elongate base 231 with an elongate arched portion 232 that is flanked by two elongate winglets 233. At the intersection of the arched portion 232 of base 231 and each of the winglets 233, there are provided two opposed elongate seal walls 234, joined to and extending away from base 231 in a diverging relationship at a divergence angle θ, where θ<180°, for example θ<90° or in the range of 40°<θ<50°. It is most preferred that θ be the same, or nearly so, as the divergence angle of the slot walls 244 described below. Thus as shown in FIG. 11A, the ends of the seal walls 234 distal from base 231 are further apart than the ends of the seal walls proximate to base 231.

At the ends of the seal walls 234 distal from base 231, each seal wall 234 is joined to an elongate arcuate buttress 235. The end of each arcuate buttress 235, distal from the seal wall 234 to which it is joined, is in turn joined to a respective planar elongate seal surface 236; thus there are two planar seal surfaces 236 in compression seal 230. The planar seal surfaces 236 extend away from the seal walls 234 in a converging relationship at a convergence angle δ, where δ<180°, for example 90°. Thus the ends of seal surfaces 236 distal from arcuate buttresses 235 are closer together than the ends of seal surfaces 236 proximate to arcuate buttresses 235. The ends of seal surfaces 236 distal from arcuate buttresses 235 are joined by an elongate seal closure 237. The base 231, seal walls 234, arcuate buttresses 235, seal surfaces 236 and seal closure 237 thereby define a hollow elongate seal chamber 238, as shown in FIG. 11A. Seal closure 237 is curved in shape toward seal chamber 238, such as to assume a cupped appearance.

Seal 230 is intended to be received in an elongate seal slot 240, shown for example in FIG. 11B. Slot 240 in general has a dovetail shape, with an elongate planar floor 241 flanked by two elongate lateral grooves 242, and with an elongate planar slot wall 244 abutting and extending from each groove 242 toward an elongate shoulder 243 at the surface of the slot 240. Thus there are two opposed shoulders 243 in seal slot 240. The planar slot walls 244 extend away from grooves 242 in a diverging relationship at a divergence angle ε, where ε<180° (for example ε<90° or in the range of 40°<ε<50°), such that the edges of slot walls 244 coincident with shoulders 243 are further apart than the edges of slot walls 244 abutting grooves 242. Compression seal 230 is dimensioned to snugly fit within slot 240, as shown in FIG. 11B, such that winglets 233 are received in grooves 242 and the arched portion 232 of base 231 is compressed sufficiently to provide a resilient force that urges winglets 233 into grooves 242 and causes seal 230 to be retained in its proper position in slot 240 during fabrication and following fabrication of the enclosure component 155.

When two enclosure components 155 on which are mounted two paired enclosure component sealing structures, one of which bears a compression seal 230, are appropriately positioned and pressed together, compression seal 230 will be squeezed against the planar exterior face 227 of the opposed seal plate 223, which causes seal closure 237 and arcuate buttresses 235 to be urged into seal chamber 238. This permits the two planar exterior faces 227 of the pressed-together seal plates 223 of the paired sealing structures to come into full contact. At the same time, arcuate buttresses 235 rotate down and seal surfaces 236 are urged into a generally coplanar relationship (with arcuate buttresses 238 functioning as hinges) with the opposing planar exterior face 227 pressing against it, to create two lines of sealing.

Compression seal 230 can be fabricated from a resilient material, such as rubber or plastic, for example polyurethane. Particular embodiments of enclosure component sealing structures utilizing the foregoing compression sealing system are described below.

D. Wall Vertical Interlock (245), Wall End Cap (246) Sealing System

FIG. 12 depicts in exploded form the junction between a wall vertical interlock 245 and a wall end cap 246. The particular junction is shown for illustrative purposes between wall portion 200 s-1 and 200 s-2, with wall vertical interlock 245 positioned on the interior vertical edge of wall portion 200 s-2 (interior vertical edge 192-2 shown in FIG. 2) and wall end cap 246 positioned on the interior vertical edge of wall portion 200 s-1 (interior vertical edge 192-1 shown in FIG. 2). In structure 150, wall vertical interlock 245 and wall end cap 246 shown in FIG. 12 are vertically-oriented.

In particular, wall vertical interlock 245 is a rigid elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the interior edge of wall portion 200 s-2, so as to cover the entirety, or substantially the entirety, of that interior edge of wall portion 200 s-2.

As shown in FIG. 12, at the mid-point of the interior face 226 of wall vertical interlock 245 there is provided an elongate key 222, which is rectangular in cross section has a length the same, or substantially the same, as the length of seal plate 223. Key 222 is received in a corresponding elongate slot formed in the interior edge reinforcement positioned on the interior vertical edge of wall portion 200 s-2, to which wall vertical interlock 245 is secured. Each of the top and bottom edges of wall vertical interlock 245 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, when bent down at a ninety degree (90°) angle. In addition, the edge of one of the slots 229 abutting the interior face 226 of wall vertical interlock 245 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.

Still referring to FIG. 12, at the mid-point of the exterior face 227 of seal plate 223 of wall vertical interlock 245 there is provided an elongate interlock slot 228, which is rectangular in cross-section and has a length the same, or substantially the same, as the length of the exterior face 227 of wall vertical interlock 245. Two elongate seal slots 240 are defined on the exterior face 227 of wall vertical interlock 245, one above interlock slot 228 and the other below interlock slot 228, as shown in FIG. 12. Each slot 240 has a length the same, or substantially the same, as the length of wall vertical interlock 245.

Wall vertical interlock 245 can be secured to the vertical edge of wall portion 200 s-2 shown in FIG. 12 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall vertical interlock 245 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

FIG. 12 additionally depicts a wall end cap 246. Wall end cap 246 shown in FIG. 12 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the exterior edge of wall portion 200 s-1, so as to cover the entirety, or substantially the entirety, of the vertical edge of wall portion 200 s-1 shown in in FIG. 12.

At the mid-point of the interior face 226 of wall end cap 246 show in in FIG. 12 there is provided an elongate key 222, which is rectangular in cross-section and has a length the same, or substantially the same, as the length of seal plate 223. Key 222 of wall end cap 246 is received in a corresponding elongate slot formed in the interior edge reinforcement, positioned on the interior vertical edge of wall portion 200 s-1, to which wall end cap 246 is secured. Each of the top and bottom edges of wall end cap 246 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, when bent down at a ninety degree (90°) angle. In addition, the edge of one of the slots 229 abutting the interior face 226 of wall end cap 246 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.

Wall end cap 246 can be secured to the vertical edge of wall portion 200 s-1 shown in FIG. 12 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 12, wall vertical interlock 245 mates with wall end cap 246. For this purpose, at the mid-point of the exterior face 227 of seal plate 223 of wall end cap 246 there is provided an elongate interlock key 247, which is rectangular in cross-section and has a length the same, or substantially the same, as the length of the exterior face 227 of wall end cap 246. Interlock key 247 mates with interlock slot 228 when wall vertical interlock 245 and wall end cap 246 are pressed together. Additionally, the two edges of wall end cap 246 are provided with elongate coupling ridges 248 which mate with elongate coupling insets 249 located at the edges of wall vertical interlock 245. Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as wall end cap 246 and wall vertical interlock 245 respectively.

Prior to mating wall vertical interlock 245 with wall end cap 246, a compression seal 230 is placed in each of the two seal slots 240 of wall vertical interlock 245, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted. When wall vertical interlock 245 with wall end cap 246 are pressed together in a mating relationship, the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between wall vertical interlock 245 and wall end cap 246.

E. I-Beam Interlock A (250), I-Beam Interlock B (251) Sealing System

FIG. 14 depicts in exploded form the junction between an I-beam interlock A 250 and an I-beam interlock B 251, each shown in cross-section. The particular junction is shown for illustrative purposes between roof portion 400 b and roof portion 400 c, with I-beam interlock A 250 positioned on the interior edge 412 c of roof portion 400 c, and with I-beam interlock B 251 positioned on first interior edge 412 b of roof portion 400 b. In structure 150, I-beam interlock A 250 and I-beam interlock B 251 shown in FIG. 14 are horizontally-oriented.

In particular, I-beam interlock A 250 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the interior edge 412 c of roof portion 400 c shown in FIG. 14, so as to cover the entirety, or substantially the entirety, of that interior edge.

As shown in FIG. 14, at the mid-point of the interior face 226 of I-beam interlock A 250 there is provided an elongate key 222, which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock A 250. Key 222 is received in a corresponding elongate slot formed in the interior edge reinforcement positioned on the horizontal edge of roof portion 400 c, to which I-beam interlock A 250 is secured. Each of the top and bottom edges of I-beam interlock A 250 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle. In addition, the edge of one of the slots 229 abutting the interior face 226 of I-beam interlock A 250 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.

Still referring to FIG. 14, in the lower half of the exterior face 227 of seal plate 223 of I-beam interlock A 250 there is provided an elongate interlock slot 228, which has a rectangular cross-section and a length the same, or substantially the same, as the length of the exterior face 227 of I-beam interlock A 250. Three elongate seal slots 240 are defined on the exterior face 227 of I-beam interlock A 250, two above interlock slot 228 and one below interlock slot 228, as shown in FIG. 14. Each seal slot 240 has a length the same, or substantially the same, as the length of I-beam interlock A 250.

I-beam interlock A 250 can be secured to the interior edge 412 c of roof portion 400 c shown in FIG. 14 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam interlock A 250 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

FIG. 14 additionally depicts an I-beam interlock B 251. I-beam interlock B 251 is a rigid elongate member that is defined by an elongate seal plate 223 having an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length and width the same, or substantially the same, as the length and width of the first interior edge 412 b of roof portion 400 b, so as to cover the entirety, or substantially the entirety, of that interior edge.

At the mid-point of the interior face 226 of I-beam interlock B 251 shown in in FIG. 14 there is provided an elongate key 222, which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock B 251. Key 222 of I-beam interlock B 251 is received in a corresponding elongate slot formed in the exterior edge reinforcement positioned on first interior edge 412 b of roof portion 400 b, to which I-beam interlock B 251 is secured. Each of the top and bottom edges of I-beam interlock B 251 define elongate locating slots 229 for receiving the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle. In addition, the edge of one of the slots 229 abutting the interior face 226 of wall end cap 246 is terminated an inset distance “I” from the opposing edge of that slot, where I is the thickness of the protective layer 218, such as magnesium oxide (MgO) board.

I-beam interlock B 251 can be secured to the first interior edge 412 b of roof portion 400 b for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of I-beam interlock B 251 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 14, I-beam interlock A 250 mates with I-beam interlock B 251. For this purpose, in the lower half of the exterior face 227 of seal plate 223 of I-beam interlock B 251 there is provided an elongate interlock key 247, which has a rectangular cross-section and a length the same, or substantially the same, as the length of I-beam interlock B 251. Interlock key 247 mates with interlock slot 228 when I-beam interlock A 250 and I-beam interlock B 251 are pressed together. Additionally, the exterior edges of I-beam interlock B 251 are provided with elongate coupling ridges 248 which mate with elongate coupling insets 249 located at the exterior edges of I-beam interlock A 250. Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as I-beam interlock A 250 and I-beam interlock B 251 respectively.

Prior to mating I-beam interlock A 250 with I-beam interlock B 251, a compression seal 230 is placed in each of the three seal slots 240 of I-beam interlock A 250, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted. When I-beam interlock A 250 and I-beam interlock B 251 are pressed together in a mating relationship, the three compression seals 230 are deformed in the manner described previously to provide six lines of sealing between I-beam interlock A 250 and I-beam interlock B 251.

F. Floor Top Plate (252), Wall End Cap (246) Sealing System

FIG. 15 depicts in exploded form the junction between a floor top plate 252 and a wall end cap 246, each shown in cross-section. The particular junction is shown for illustrative purposes between wall component 200R and floor portion 300 a, with floor top plate 252 positioned along the upper surface of floor portion 300 a adjacent second longitudinal floor edge 119, and with wall end cap 246 positioned on the bottom edge of wall component 200R. In structure 150, wall 200R shown in FIG. 15 is vertically oriented and floor portion 300 a is horizontally oriented.

In particular, floor top plate 252 in FIG. 15 is a rigid elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length the same, or substantially the same, as the length of second longitudinal floor edge 119, so as to cover the top edge of floor portion 300 a proximate to second longitudinal floor edge 119. Seal plate 223 of floor top plate 252 has a width the same, or substantially the same, as the width of wall component 200R. The floor top plate 252 preferably has a thickness “J” sufficient to accommodate the thickness of any protective layer 218 and/or flooring used to surface floor portion 300 a, such as stone, wood or carpeting.

As shown in FIG. 15, at the exterior edge of the interior face 226 of floor top plate 252, proximate to second longitudinal floor edge 119, there is provided a series of elongate stepped locating ridges 254. These stepped locating ridges, which have a length the same, or substantially the same, as the length of floor top plate 252, mesh with the corresponding stepped locating ridges 253 shown on I-beam end cap 221 depicted in FIG. 10 and with dashed lines in FIG. 15.

Still referring to FIG. 15, at the mid-point of the exterior face 227 of seal plate 223 of floor top plate 252 there is provided an elongate interlock slot 228, which has a rectangular cross-section and a length the same, or substantially the same, as the length of floor top plate 252. Two elongate seal slots 240 are defined on the exterior face 227 of floor top plate 252, one on each side of interlock slot 228, as shown in FIG. 15. Each slot 240 has a length the same, or substantially the same, as the length of floor top plate 252.

Floor top plate 252 can be secured to the top edge of floor portion 300 a proximate to second longitudinal floor edge 119 shown in FIG. 15 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of floor top plate 252 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

FIG. 15 additionally depicts a wall end cap 246 positioned along the bottom edge of wall component 200R. The design of wall end cap 246 was previously described in connection with FIG. 12. The seal plate 223 of wall end cap 246 shown in FIG. 15 has a length and width the same, or substantially the same, as the length and width of the bottom edge of wall component 200R, so as to cover the entirety, or substantially the entirety, of the bottom edge of wall component 200R shown in in FIG. 15.

Wall end cap 246 can be secured to the bottom edge of wall component 200R shown in FIG. 15 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 15, floor top plate 252 mates with wall end cap 246. For this purpose, the interlock key 247 of wall end cap 246 is provided with a length the same, or substantially the same, as the length of the exterior face 227 of floor top plate 252. That interlock key 247 mates with the interlock slot 228 of floor top plate 252 when floor top plate 252 and wall end cap 246 are pressed together, with the elongate coupling ridges 248 of wall end cap 246 mating with the elongate coupling insets 249 of floor top plate 252. Coupling ridges 248 and coupling insets 249 can have the same, or approximately the same, lengths as wall end cap 246 and floor top plate 252 respectively.

Prior to mating wall end cap 246 and floor top plate 252, a compression seal 230 is placed in each of the two seal slots 240 of floor top plate 252, with each seal 230 having the same, or approximately the same, length as the seal slot 240 in which it is inserted. When wall vertical interlock 245 and wall end cap 246 are pressed together in a mating relationship, the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between wall end cap 246 and floor top plate 252.

G. Roof Bottom Plate (255), Wall End Cap (246) Sealing System

FIG. 13 depicts in exploded form the junction between a roof bottom plate 255 and a wall end cap 246, each shown in cross-section. The particular junction shown for illustrative purposes is between wall component 200R and roof portion 400 a, with roof bottom plate 255 positioned along the lower face of roof portion 400 a adjacent second longitudinal roof edge 416, and wall end cap 246 positioned on the top edge of wall component 200R. In structure 150, wall component 200R in FIG. 13 is vertically oriented and roof portion 400 a is horizontally oriented.

The design of roof bottom plate 255 shown in FIG. 13 is substantially the same as floor top plate 252 shown in FIG. 15, except that roof bottom plate 255 is thinner because it need not accommodate the thickness of any flooring; for example, roof bottom plate 255 can have a thickness “I”, equal to the thickness of an abutting protective layer 218, such as MgO board. Roof bottom plate 255 in FIG. 13 is a rigid elongate member that has an elongate seal plate 223 with an elongate planar interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 of roof bottom plate 255 has a length the same, or substantially the same, as the length of second longitudinal roof edge 416, so as to cover the bottom edge of roof portion 400 a proximate to second longitudinal roof edge 416. Seal plate 223 of roof bottom plate 255 has a width the same, or substantially the same, as the width of wall component 200R.

As shown in FIG. 13, at the exterior edge of the interior face 226 of roof bottom plate 255, proximate to second longitudinal roof edge 416, there is provided a series of elongate stepped locating ridges 254. These stepped locating ridges, which have a length the same, or substantially the same, as the length of roof bottom plate 255, mesh with the corresponding stepped locating ridges 253 of wall end cap 221 depicted in FIG. 10 and with dashed lines in FIG. 13, and positioned at the exterior edge of roof portion 400 a.

Still referring to FIG. 13, at the mid-point of the exterior face 227 of seal plate 223 of roof bottom plate 255 there is provided an elongate interlock slot 228, which has a rectangular cross-section and a length the same, or substantially the same, as the length of roof bottom plate 255. There are two elongate seal slots 240 defined on the exterior face 227 of roof bottom plate 255, one on each side of interlock slot 228, as shown in FIG. 13. Each seal slot 240 has a length the same, or substantially the same, as the length of roof bottom plate 255.

Roof bottom plate 255 can be secured to the bottom face of roof portion 400 a shown in FIG. 13 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of roof bottom plate 255 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

FIG. 13 additionally depicts a wall end cap 246 positioned along the top edge of wall component 200R. The design of wall end cap 246 was previously described in connection with FIG. 12. The seal plate 223 of wall end cap 246 shown in FIG. 13 has a length and width the same, or substantially the same, as the length and width of the top edge of wall component 200R, so as to cover the entirety, or substantially the entirety, of the top edge of wall component 200R. Wall end cap 246 can be fastened to that top edge for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end cap 246 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 13, roof bottom plate 255 mates with wall end cap 246. For this purpose, the interlock key 247 of wall end cap 246 is provided with a length the same, or substantially the same, as the length of roof bottom plate 255. That interlock key 247 mates with the interlock slot 228 of roof bottom plate 255 when roof bottom plate 255 and wall end cap 246 are pressed together, with the elongate coupling ridges 248 of wall end cap 246 mating with elongate coupling insets 249 of roof bottom plate 255. Coupling ridges 248 and coupling insets 249 can be the same, or approximately the same, as the lengths of wall end cap 246 and roof bottom plate 255 respectively.

Prior to mating wall end cap 246 and roof bottom plate 255, a compression seal 230 is placed in each of the two seal slots 240 of roof bottom plate 255, with each seal 230 having the same, or approximately the same, length as the slot 240 in which it is inserted. When roof bottom plate 255 and wall end cap 246 are pressed together in a mating relationship, the two compression seals 230 are deformed in the manner described previously to provide four lines of sealing between roof bottom plate 255 and wall end cap 246.

H. Shear Seal (260)

A number of the enclosure component sealing systems described herein and utilized in structure 150 include a shear seal system. An element of that shear seal system is a shear seal 260.

Shear seal 260, which is shown in cross-section in FIG. 16A, is an elongate member having a planar elongate base 231 flanked by two elongate winglets 233. At the intersection of base 231 and each of the winglets 233, there is provided two opposed elongate seal walls 234 (individually referred to as seal walls 234A, 234B), joined to and extending away from base 231 in a diverging relationship at a divergence angle λ where λ<180°, for example λ<90° or in the range of 40°<λ<50°. It is most preferred that λ be the same, or nearly so, as the divergence angle ε of the slot walls 244 shown in FIG. 11B. Thus as shown in FIG. 16A, the ends of the seal walls 234 distal from base 231 are further apart than the ends of the seal walls 234 proximate to base 231.

At the end of seal wall 234B distal from base 231, seal wall 234B is joined to an elongate seal closure 237, a planar surface oriented at an upward angle α (relative to the planar orientation of base 231) away from seal wall 234B in a direction toward an elongate seal support 239, described below, with α<90°. A planar cantilevered seal surface 257 is joined to the edge of seal closure 237 that is distal from seal wall 234B, as shown in FIG. 16A.

At the end of seal wall 234A distal from base 231, seal wall 234A is joined to the elongate seal support 239. Proximate to seal wall 234A, seal support 239 comprises an elongate planar region oriented parallel to base 231. Distal from seal wall 234A, seal support 239 comprises an elongate arcuate buttress region. The edge of the arcuate buttress region of seal support 239, which is distal from seal wall 234A, joins cantilevered seal surface 257 proximate to the junction of cantilevered seal surface 257 and seal closure 237 to define a hollow seal chamber 238. Planar cantilevered seal surface 257 is oriented at an upward angle β away from the junction of arcuate buttress 235 and seal closure 237 and terminates at a free end 258, with β<90°, for example β>α.

Shear seal 260 is intended to be received in an elongate seal slot 240, shown for example in FIG. 16B, which has the same geometry as the seal slots 40 utilized to receive compression seals 230. Shear seal 260 is dimensioned to snugly fit within slot 240, such that winglets 233 of seal 260 are received in grooves 242 of slot 240. An exemplary placement of a shear seal 260 is depicted in FIG. 16B, which shows a shear seal 260 placed within the slot 240 of a wall end interlock A 262, described further below. As can be seen, when shear seal 260 is properly positioned in slot 240, both seal wall 234A and seal wall 234B terminate below the level of exterior face 227 of wall end interlock A 262, with seal wall 234A (underlying planar cantilevered seal surface 257) terminating below the level at which seal wall 234B terminates.

Shear seal 260 is preferably utilized where two enclosure components 155 are laterally moved during unfolding, one over the other. In such an instance, the two enclosure components 155 are provided with paired enclosure component sealing structures, with one enclosure component sealing structure mounted on one of the enclosure components 155 (such as on an exterior edge), and the other enclosure component sealing structure mounted on the other of the enclosure component structures 155 (such as on an interior face). Each of the paired enclosure component sealing structures has a shear seal 260, with the two shear seals 260 being oppositely oriented; that is to say, the cantilevered seal surface 257 of each is oriented away from the cantilevered seal surface 257 of the other, and each is oriented in the direction of relative movement. Thus in the case of each of the two shear seals 260, the lateral movement of one enclosure component 155, relative to the other, is in the direction from seal wall 234B toward seal wall 234A. This lateral movement flattens the cantilevered seal surface 257, as well as the seal closure 237, and squeezes down each shear seal 260, such that its seal closure 237 and seal support 239 are urged into seal chamber 238. This permits the opposing planar exterior faces 227 of each of the two enclosure component sealing structures to come into full contact. At the same time, the cantilevered seal surface 257 and seal closure 237 of each shear seal 260 are urged into a generally coplanar relationship, with the planar exterior face 227 of the opposing enclosure component seal structure pressing against them, to create an elongate area of sealing.

Shear seal 260 can be fabricated from a resilient material, such as rubber or plastic, for example polyurethane. Particular embodiments of enclosure component sealing structures utilizing the foregoing compression sealing system are described below.

I. Wall End Interlock A (262), Floor Top Interlock (261) Sealing System

FIG. 17 depicts in exploded form the junction between a floor top interlock 261 and a wall end interlock A 262, each shown in cross-section. The particular junction is shown for illustrative purposes between wall portion 200 s-2 and floor portion 300 b, with floor top interlock 261 positioned along the upper face of floor portion 300 b adjacent first transverse floor edge 120, and with wall end interlock A 262 positioned on the bottom edge of wall portion 200 s-2. In structure 150, wall portion 200 s-2 in FIG. 17 is vertically oriented and floor portion 300 b is horizontally oriented.

In particular, floor top interlock 261 shown in FIG. 17 is a rigid elongate member that has an elongate seal plate 223 with an interior face 226 and an opposing planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length the same, or substantially the same, as the dimension of floor portion 300 b coinciding with first transverse floor edge 120, so as to cover the top edge of floor portion 300 b proximate to first transverse floor edge 120. Seal plate 223 of floor top interlock 261 has a width the same, or substantially the same, as the width of wall portion 200 s-2. The floor top interlock 261 preferably has a thickness “J” at its interior edge, as shown in FIG. 17, sufficient to accommodate the thickness of any protective layer 218 and/or flooring used to surface floor portion 300 b, such as stone, wood or carpeting.

As shown in FIG. 17, at the exterior edge of the interior face 226 of floor top interlock 261, adjacent first transverse floor edge 120, there is provided a series of elongate stepped locating ridges 254. These stepped locating ridges 254, which have a length the same, or substantially the same, as the length of floor top interlock 261, mesh with the corresponding stepped locating ridges 253. shown on the wall end cap 221 depicted in FIG. 10. Such a wall end cap 221 is located at the exterior edge of wall portion 300 b, as indicated in FIG. 17 by dashed lines.

Still referring to FIG. 17, an elongate seal slot 240 is defined on the exterior face 227 of floor top interlock 261, proximate to the exterior edge of floor portion 300 b (such exterior edge coincides with first transverse floor edge 120). Seal slot 240 has a length the same, or substantially the same, as the length of floor top interlock 261.

Floor top interlock 261 can be secured to the top edge of floor portion 300 b at first transverse floor edge 120 shown in FIG. 17 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of floor top interlock 261 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

Wall end interlock A 262, also shown in FIG. 17, is a rigid elongate member that has an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. The seal plate 223 of wall end interlock A 262 has a length and width the same, or substantially the same, as the length and width of the bottom edge of wall portion 200 s-2, so as to cover the entirety, or substantially the entirety, of the bottom edge of wall portion 200 s-2, as shown in in FIG. 17.

At the mid-point of the interior face 226 of seal plate 223 of wall end interlock A 262, there is provided an elongate key 222, which has a rectangular cross section and a length the same, or substantially the same, as the length of wall end interlock A 262. Key 222 is received in a corresponding elongate slot formed in the exterior edge reinforcement positioned on the bottom edge of the wall portion 200 s-2 to which wall end interlock A 262 is secured.

Again referring to FIG. 17, an elongate seal slot 240 is defined on the exterior face 227 of wall end interlock A 262, toward the interior edge of wall end interlock A 262 (distal from first transverse floor edge 120). This seal slot 240 has a length the same, or substantially the same, as the length of wall end interlock A 262. Additionally, each of the interior and exterior edges of wall end interlock A 262 define locating slots 229. In the case where the enclosure component 155, in this case wall portion 200 s-2, utilizes the enclosure component laminate design shown in FIG. 7, locating slots 229 receive the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.

Wall end interlock A 262 can be fastened to the bottom edge of wall portion 200 s-2 for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock A 262 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 17, floor top interlock 261 mates with wall end interlock A 262. Prior to mating, a shear seal 260 is placed in the seal slot 240 of floor top interlock 261, and a shear seal 260 is placed in the seal slot 240 of wall end interlock A 262. The shear seals 260 placed in the seals slots 240 of floor top interlock 261 and wall end interlock A 262 each has the same, or approximately the same, length as the slot 240 in which it is inserted.

Mating of floor top interlock 261 with wall end interlock A 262 occurs by the bottom edge of wall portion 200 s-2 moving over the top surface of floor portion 300 b, from a folded position to an unfolded position. Thus in the arrangement shown in FIG. 17, such mating will correspond to a movement of wall portion 200 s-2 from the right-hand side of the figure toward the left, with wall end interlock A 262 sliding over floor top interlock 261 until the fully unfolded position is reached. In that fully unfolded position, the shear seal 260 in floor top interlock 261, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of wall end interlock A 262; and the shear seal 260 in wall end interlock A 262, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of floor top interlock 261. Consistent with this movement, the shear seal 260 placed in seal slot 240 of floor top interlock 261 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the exterior edge of floor top interlock 261 (toward first transverse floor edge 120), and the shear seal 260 placed in the seal slot 240 of wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the interior edge of wall end interlock A 262 (away from first transverse floor edge 120).

To facilitate mating, it is preferred that planar exterior face 227 of floor top interlock 261 not be parallel to the interior face 226 of floor top interlock 261, or to the top face of wall portion 300 b, but rather be inclined downward, in the direction moving away from first transverse floor edge 120, at an angle γ, as shown in FIG. 17. Likewise, it is preferred that planar exterior face 227 of wall end interlock A 262 be inclined upward, in the direction moving toward first transverse floor edge 120, at the same angle γ, as shown in FIG. 17. Accordingly, when bottom edge of wall portion 200 s-2 moves over the top surface of floor portion 300 b, from a folded position to an unfolded position, the shear seals 260 located in slots 240 of floor top interlock 261 and wall end interlock A 262 will be compressed by the sliding movement of wall end interlock A 262 to provide two elongate sealing areas between floor portion 300 b and wall portion 200 s-2. Also to facilitate mating, there is shown in FIG. 17 a step-down 268 on the exterior face 227 of wall end interlock A 262. Step-down 268 is an abrupt reduction in the thickness of wall end interlock A 262, in the direction moving from the inside edge of wall end interlock A 262 toward the outside edge of wall end interlock A 262, which outside edge in the case of the junction depicted in FIG. 17 is proximate first transverse floor edge 120 when wall portion 200 s-2 is in the fully unfolded position. Step-down 268 is located between the slot 240 and the outside edge of wall end interlock A 262. There is also shown in FIG. 17 a corresponding step-up 269 on the exterior face 227 of floor top interlock 261. Step-up 269 is an abrupt increase in the thickness of floor top interlock 261, in the direction moving from the inside edge of floor top interlock 261 toward the outside edge of floor top interlock 261, which outside edge in the case of the junction depicted in FIG. 17 is proximate first transverse floor edge 120 when floor portion 300 b is in the fully unfolded position. Step-up 269 is located between the slot 240 and the inside edge of floor top interlock 261 (distal from first transverse floor edge 120). Step-down 268 and step-up 269 are appropriately located to act as a “stop” and insure correct alignment of wall end interlock A 262 with floor top interlock 261 as wall end interlock A 262 slides over floor top interlock 261.

J. Wall End Interlock B (263), Wall End Interlock A (262) Sealing System

FIG. 18 depicts in exploded form the junction between a wall end interlock B 263 and a wall end interlock A 262, each shown in cross-section. The particular junction is shown for illustrative purposes between wall portion 200 s-2 and wall component 200P, with wall end interlock B 263 positioned on the interior edge of wall component 200P proximate first transverse edge 108 and wall end interlock A 262 positioned on the vertical edge of wall portion 200 s-2 proximate first longitudinal edge 106. In structure 150, wall portion 200 s-2 depicted in FIG. 18 is vertically oriented and wall component 200P is vertically oriented.

In particular, wall end interlock B 263 in FIG. 18 is an elongate member that has an elongate seal plate 223 with an elongate interior face 226 and an opposing elongate planar exterior face 227. The exterior face 227 preferably is hard and smooth to provide a good sealing surface. Seal plate 223 has a length the same, or substantially the same, as the height of wall component 200P when unfolded, so as to cover the interior edge of wall component 200P proximate to first transverse edge 108. Seal plate 223 of wall end interlock B 263 has a width the same, or substantially the same, as the width of wall portion 200 s-2. In general terms, the design of wall end interlock B 263 is substantially the same as floor top interlock 261 depicted in FIG. 17, except wall end interlock B 263 is thinner because it need not accommodate any flooring; for example, wall end interlock B 263 can have a thickness “I” (not shown in FIG. 18) at its interior edge equal to the thickness of an abutting protective layer 218, such as MgO board.

Still referring to FIG. 18, an elongate seal slot 240 is defined on the exterior face 227 of wall end interlock B 263, proximate the interior edge of wall component 200P positioned adjacent to first longitudinal edge 106. Seal slot 240 has a length the same, or substantially the same, as the length of wall end interlock B 263.

Wall end interlock B 263 can be secured to the interior edge of wall component 200P as shown in FIG. 18 for example by adhesive applied to interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock B 263 and driven through the exterior face 227, or by utilizing a combination of adhesive and fasteners.

FIG. 18 additionally shows a wall end interlock A 262 positioned along the depicted vertical edge of wall portion 200 s-2. The design of wall end interlock A 262 was previously disclosed in connection with FIG. 17. The seal plate 223 of the wall end interlock A 262 shown in FIG. 18 has a length and width the same, or substantially the same, as the length and width of the depicted vertical edge of wall portion 200 s-2, so as to cover the entirety, or substantially the entirety, of that vertical edge of wall portion 200 s-2, as shown in in FIG. 18. The elongate rectangular key 222 of wall end interlock A 262 shown in FIG. 18 has a length the same, or substantially the same, as the length of that wall end interlock A 262. Key 222 is received in a corresponding elongate slot formed in the exterior edge reinforcement positioned on the vertical edge of the wall portion 200 s-2 to which wall end interlock A 262 is secured. The seal slot 240 of wall end interlock A 262 shown in FIG. 18 has a length the same, or substantially the same, as the length of that wall end interlock A 262. In the case where the enclosure component 155, in this case wall portion 200 s-2, utilizes the enclosure component laminate design shown in FIG. 7, the locating slots 229 of wall end interlock A 262 shown in FIG. 18 receive the edge portions of sheet metal layers 205 and 216, bent down at a ninety degree (90°) angle.

Wall end interlock A 262 can be secured to the vertical edge of wall portion 200 s-2 shown in FIG. 18 for example by adhesive applied to its interior face 226, or by fasteners, such as screw or nail fasteners, spaced apart along the length of wall end interlock A 262 and driven through its exterior face 227, or by utilizing a combination of adhesive and fasteners.

In FIG. 18, wall end interlock A 262 mates with a wall end interlock B 263. Prior to mating, a shear seal 260 is placed in the seal slot 240 of wall end interlock A 262, and a shear seal 260 is placed in the seal slot 240 of wall end interlock B 263. Each of the shear seals 260 placed in the seals slots 240 of wall end interlock A 262 and a wall end interlock B 263 has the same, or approximately the same, length as the slot 240 in which it is inserted.

Mating of wall end interlock A 262 and a wall end interlock B 263 occurs by the vertical edge of wall portion 200 s-2 depicted in FIG. 18 swinging toward and across the interior surface of wall component 200P, as wall portion 200 s-2 moves from a folded position to an unfolded position. Thus in the arrangement shown in FIG. 18, such mating will correspond to a movement of wall portion 200 s-2 from the top of the figure toward the bottom, with wall end interlock A 262 sliding across wall end interlock B 263 until the fully unfolded position is reached. In that fully unfolded position, the shear seal 260 in wall end interlock A 262, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of wall end interlock B 263; and the shear seal 260 in wall end interlock B 263, and particularly its seal surface 257, will be in pressing contact with the exterior face 227 of wall end interlock A 262. Consistent with this movement, the shear seal 260 placed in seal slot 240 of floor top interlock B 263 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the exterior edge of wall end interlock B 263 (toward first transverse edge 108), and the shear seal 260 placed in the seal slot 240 of wall end interlock A 262 is preferably oriented so that the free end 258 of its cantilevered seal surface 257 is directed toward the interior edge of wall end interlock A 262 (away from first transverse edge 108).

To facilitate mating, it is preferred that planar exterior face 227 of wall end interlock B 263 not be parallel to the interior face 226 of wall end interlock B or to the interior face of wall component 200P, but rather be inclined at an angle γ, as shown in FIG. 17, so that seal plate 223 of wall end interlock B 263 becomes progressively thinner moving away from first transverse edge 108. Likewise, it is preferred that planar exterior face 227 of wall end interlock A 262 be inclined at the same angle γ, as shown in FIG. 17, so that seal plate 223 of wall end interlock A 262 becomes progressively thicker moving away from first transverse edge 108. Accordingly, when vertical edge of wall portion 200 s-2 swings toward and across the interior surface of wall component 200P, from a folded position to an unfolded position, the shear seals 260 located in slots 240 of floor end interlock A 262 and wall end interlock B 263 will be compressed by the sliding movement of wall end interlock A 262 to provide two elongate sealing areas between wall component 200P and wall portion 200 s-2. Also to facilitate mating, as previously described a step-down 268 is provided on the exterior face 227 of wall end interlock A 262. Step-down 268 is an abrupt reduction in the thickness of wall end interlock A 262, in the direction moving from the inside edge of wall end interlock A 262 toward the outside edge of wall end interlock A 262, which outside edge in the case of the junction depicted in FIG. 18 is proximate first transverse edge 108 when wall portion 200 s-2 is in the fully unfolded position. Step-down 268 is positioned between the slot 240 and the outside edge of wall end interlock A 262 (proximate transverse edge 108), as depicted in FIG. 18. Also as depicted in FIG. 18, a corresponding step-up 269 is provided on the exterior face 227 of wall end interlock B 263. Step-up 269 is an abrupt increase in thickness of wall end interlock B 263, in the direction moving from the inside edge of wall end interlock B 263 toward the outside edge of wall end interlock B 263, which outside edge in the case of the junction depicted in FIG. 18 is proximate first transverse edge 108. Step-up 269 is positioned between the slot 240 and the inside edge of wall end interlock B 263 (distal from first transverse edge 108). Step-down 268 and step-up 269 are appropriately located to act as a “stop” and insure correct alignment of wall end interlock A 262 with wall end interlock B 263 as wall end interlock A 262 slides across wall end interlock B 263.

K. Closure Boards

The two closure boards of these inventions, namely perimeter board 310 and roof skirt board 280, are described below.

Perimeter Board (310). The exterior edges of floor component 300, or portions thereof, are optionally provided with a perimeter board 310.

FIG. 19A depicts in cross section an exemplary positioning of perimeter board 310. In particular, perimeter board 310 is designed to be positioned against an I-beam end cap 221, in this instance the I-beam end cap 221 located on an exterior edge of floor portion 300 a. Perimeter board 310 includes an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. Perimeter board 310 has such length as is desired, such as to span the entirety of the exterior edge of floor portion 300 a. As shown in FIG. 19A, the width of perimeter board 310 can be sufficient to capture the thickness of the floor component 300 a, or floor portion thereof against which it is positioned, plus a portion of the abutting wall component 200 or wall component portion.

The interior face 226 of perimeter board 310 includes an elongate locating key 264, which is rectangular in cross section and dimensioned to be received in accessory slot 224 of I-beam end cap 221. Locating key 264 can be the same length as the perimeter board 310, or can comprise space apart discrete segments. The interior face 226 of perimeter board 310 in FIG. 19A also includes a plurality of elongate clearance slots 266, rectangular in cross section in the embodiment shown, and having a length the same as, or substantially the same as, the length of perimeter board 310. Clearance slots 266 are preferably located so as to be positioned over locating grooves 225 of I-beam end cap 221 when locating key 264 is received in accessory slot 224. When so located, clearance slots 266 provide space for fastener heads driven into locating grooves 225 of I-beam end cap 221 so that perimeter board 310 can be snugly positioned against I-beam end cap 221.

The exterior face 227 of perimeter board 310 depicted in FIG. 19A includes two elongate fastener slots 265, each of which has a dovetail shape in cross section in the embodiment shown, and a length the same as, or substantially the same as, the length of perimeter board 310. A locating groove 225 is provided in each fastener slot 265, so as to facilitate the accurate positioning of nails or other fasteners utilized to secure perimeter board 310 to abutting components.

FIG. 19B depicts in cross section the positioning of I-beam end cap 221, floor top plate 252, wall end cap 246 and perimeter board 310 relative to each other at a junction between wall component 200R and floor portion 300 a. As can be seen, perimeter board 310 masks this junction from external view to achieve a more attractive appearance, as well as providing an additional barrier against the ingress of soil, dust, rain and the like. A resilient strip 267, such as those shown in FIG. 19B, can be snapped into each of the fastener slots 265 to cover any nail or fastener heads exposed in those slots.

Roof Skirt Board. The exterior edges of roof component 400, or portions thereof, are optionally provided with a roof skirt board 280.

FIG. 20 depicts in cross section an exemplary positioning of roof skirt board 280. In particular, roof skirt board 280 is designed to be positioned against an I-beam end cap 221, in this instance the I-beam end cap 221 located on an exterior edge of roof portion 400 a. Roof skirt board 280 includes an elongate seal plate 223 with an interior face 226 and an opposing exterior face 227. Roof skirt board 280 has such length as is desired, such as to span the entirety of the exterior edge of roof portion 400 a. As shown in FIG. 20, the width of roof skirt board 280 can be sufficient to capture the thickness of the roof component 400, or portion thereof against which it is positioned, plus a portion of the abutting wall component 200 or wall portion.

The interior face 226 of roof skirt board 280 includes an elongate cinch key 278, which is preferably serpentine in cross section and dimensioned to be received in accessory slot 224 of I-beam end cap 221. Cinch key 278 can be the same length as the perimeter board 310, or can comprise space apart discrete segments. In turn, the exterior face 227 of roof skirt board 280 includes an elongate fastener slot 265 positioned over cinch key 278. Fastener slot 265 has a dovetail shape in cross section in the embodiment shown, and a length the same as, or substantially the same as, the length of roof skirt board 280. An elongate locating groove 225 is provided in the fastener slot 265 of roof skirt board 280, and provides a visual indication of where to place fasteners during construction.

Roof skirt board 280 facilitates the securing of roofing material, such as thermoplastic polyolefin membrane, to wall components 200. After fully unfolding the roof portions, such roofing material is optionally used to cover the top of roof component 400. The roofing material extending beyond roof component 400 is then folded down to extend between exterior face 227 of I-beam end cap 221 of roof portion 400 a shown in FIG. 20 and interior face 226 of roof skirt board 280. After the roofing material is so positioned, nails or other fasteners are driven at spaced intervals along locating groove 225, to press roof skirt board 280 against the roofing material and secure the roofing material in place between roof skirt board 280 and I-beam end cap 221. Cinch key 278, if provided with a serpentine or like cross section, provides additional area so as to better capture the roofing material. An elongate resilient strip 267, such as the one shown in FIG. 20, can be snapped into fastener slot 265 to cover any nail or fastener heads exposed in this slot.

Enclosure Component Sealing Structure Materials

The enclosure component sealing structures described herein can be fabricated from a number of materials, such as wood, aluminum, plastics and the like. It is preferred to fabricate the enclosure component sealing structures from foamed polyvinyl chloride (PVC), particularly Celuka foamed PVC. This material provides a strong, impact and crack-resistant lightweight material with a hard attractive exterior, which, in addition to contributing a sealing function, additionally contributes to the structural rigidity of the enclosure components 155.

Enclosure Component Sealing Structure Exemplary Placements

The exploded views in FIGS. 21A and 21B of structure 150 depicted in FIG. 1 provide exemplary placements of the enclosure component sealing structures described herein. For illustrative purposes to better understand some of these exemplary placements, certain of the enclosure component sealing structures shown in FIG. 21 are shown slightly separated from the enclosure component 155 to which they are fastened.

Referring to FIG. 21A, I-beam end caps 221 can be utilized to seal the horizontal exterior edges of floor portion 300 a (three placements), floor portion 300 b (three placements), roof portion 300 a (three placements), roof portion 300 b (two placements) and roof portion 300 c (three placements). Further, as shown in FIG. 21B and in detail in FIG. 12, the hinged junction between wall portion 200 s-1 and 200 s-2 can be sealed by positioning a wall end cap 246 on the vertical edge of wall portion 200 s-1 and a wall vertical interlock 245 on the vertical edge of wall portion 200 s-2. Likewise, the hinged vertical junction between wall portion 200 s-3 and 200 s-4 can be sealed as shown in FIG. 21B by positioning a wall end cap 246 on the hinged vertical edge of wall portion 200 s-3 and a wall vertical interlock 245 on the hinged vertical edge of wall portion 200 s-4.

In addition, as shown in FIGS. 21A and 21B, and in detail in FIG. 13, the horizontal junction between wall component 200R and roof portion 400 a can be sealed by positioning a roof bottom plate 255 on the bottom face of roof portion 400 a overlying wall component 200R and by positioning a wall end cap 246 on the horizontal edge of wall component 200R which supports roof portion 400 a. A like seal arrangement can be used to seal the horizontal junctions between roof portions 400 a, 400 b and 400 c, and wall portions 200 s-1 through 200 s-4 (unfolded roof portion 400 b will rest on unfolded wall portion 200 s-2 and also on a section of wall portion 200 s-1, as can be appreciated from FIG. 3), as well as to seal the horizontal junction between roof portion 400 c and wall component 200P. The two vertical exterior edges of wall component 200R can each be sealed by positioning on each of them a wall end cap 246.

In a comparable manner, as shown in FIGS. 21A, 21B and in detail in FIG. 15, the horizontal junction between wall component 200R and floor portion 300 a can be sealed by positioning a wall end cap 246 on the horizontal edge of wall component 200R resting on floor portion 300 a and by positioning on the top face of floor portion 300 a underlying wall component 200R a floor top plate 252. A like seal arrangement can be used to seal the horizontal junctions between floor portion 300 b and wall component 200P, and between floor portion 300 a and wall portions 200 s-1 and 200 s-3, up to the point where wall portion 200 s-1 meets wall portion 200 s-2, and up to the point where wall portion 200 s-3 meets wall portion 200 s-4. The two vertical exterior edges of wall component 200P can be sealed by positioning on each of them a wall end cap 246.

Furthermore, the hinged horizontal junction between roof portion 400 b and roof portion 400 c, as shown in FIG. 21A and in detail in FIG. 14, can be sealed by positioning an I-beam interlock A 250 on interior edge 412 c of roof portion 400 c, and an I-beam interlock B 251 on first interior edge 412 b of roof portion 400 b. Similarly, the hinged horizontal junction between roof portion 400 a and roof portion 400 b shown in FIG. 21A can be sealed by positioning an I-beam interlock A 250 on second interior edge 412 b of roof portion 400 b, and an I-beam interlock B 251 on interior edge 412 a of roof portion 400 a. In like manner, the hinged horizontal junction between floor portion 300 a and floor portion 300 b can be sealed by positioning an I-beam interlock A 250 on the interior edge 301 b of floor portion 300 b and an I-beam interlock B 251 on the interior edge 301 a of floor portion 300 a.

Referring now to FIGS. 21A, 21B and in detail to FIG. 17, the horizontal junction between wall portion 200 s-2 and floor portions 300 a, 300 b can be sealed by positioning a wall end interlock A 262 on the bottom edge of wall portion 200 s-2 and a floor top interlock 261 on the regions of the upper face of floor portions 300 a and 300 b underlying wall portion 200 s-2 when wall portion 200 s-2 is in its fully unfolded position. The horizontal junction between wall portion 200 s-4 and floor portions 300 a and 300 b when wall portion 200 s-4 in its fully unfolded position can be sealed similarly.

Finally, referring to FIG. 21B and in detail to FIG. 18, the vertical junction between wall portion 200 s-2 and wall component 200P can be sealed by positioning a wall end interlock A 262 on the vertical edge of wall portion 200 s-2 that is adjacent to wall component 200P when both wall portion 200 s-2 and wall component 200P are in their fully unfolded positions, and by positioning a wall end interlock B 263 on the region of the interior face of wall component 200P that is adjacent wall portion 200 s-2 when both wall portion 200 s-2 and wall component 200P are in their fully unfolded positions. The vertical junction between wall portion 200 s-4 and wall component 200P can be sealed in like manner

Enclosure Component Manufacture

A. General Description

FIG. 22 depicts a facility 10 for fabricating the enclosure components 155. The facility comprises a conveyor table 50, a press table 51, and in the embodiment shown in FIG. 22, four material turntables 52A, 52B, 52C and 52D and four robotic assemblers 54A, 54B, 54C and 54D. There is also an adhesive spray gantry 55 straddling the conveyor table 50. Whether partitioned or not, all of the enclosure components 155—wall components 200, floor components 300 and roof components 400—can be formed on the same facility 10.

Conveyor table 50 is provided with a plurality of cylindrical rollers to facilitate movement of work pieces from the assembly area 56 onto the press table 51. The enclosure components 155 are built up, layer upon layer, in the assembly area 56, and then moved into the press table 51. The movement of materials from turntables 52A, 52B, 52C and 52D onto conveyor table 50 can be done manually, by manufacturing personnel. Alternatively, robotic assemblers, such as robotic assemblers 54A, 54B, 54C and 54D depicted in FIGS. 22 and 23, can be employed to carry out some or all of such movement, either under the control of manufacturing personnel, or under the control of an appropriately-programmed computer controller.

Press table 51 preferably employs a vacuum bag system to press together the layers forming enclosure components 155. Spray gantry 55 is movable over conveyor table 50 between a first position proximate to press table 51 and a second position distal from press table 51. Spray gantry 55 is provided with a number of downward-directed spray heads for spraying adhesive, such as polyurethane based construction adhesive, onto the work pieces, as directed.

The facility 10 is designed to fabricate two enclosure components 155 simultaneously. Thus robotic assemblers 54A and 54B are positioned as opposed pairs with conveyor table 50 between them, as shown in FIG. 22, and are used to move sheets and panels from turntables 52A and 52B, respectively, to appropriate locations on conveyor table 50 to form a first enclosure component 155. Likewise, robotic assemblers 54C and 54D are positioned as opposed pairs with conveyor table 50 between them, as shown in FIG. 5, and are used to move sheets and panels from turntables 52C and 52D, respectively, to appropriate locations on conveyor table 50 to form a second enclosure component 155. Looking down at turntables 52A-52D in FIG. 22 and assuming them to have the face of a clock (with the twelve o′clock position being closest to press table 51), robotic assemblers 54A and 54C are adapted to move sheets and panels from the access positions of turntables 52A and 52C respectively (proximate the nine o′clock position on turntables 52A and 52C), to conveyor table 50. Correspondingly, robotic assemblers 54B and 54D are adapted to move sheets and panels from the access positions of turntables 52B and 52D respectively (proximate the three o′clock position on each of turntables 52B and 52D), to conveyor table 50.

In the facility 10 shown in FIG. 22, the access positions on turntables 52A-52D are made sufficiently large so as to be able to position two or more sheets and/or panels adjacent to each other at those access positions. This permits robotic assemblers 54A-54D to have access to two or more sheets and/or panels that are not stacked, one or top of another, without the need to rotate further the turntables 52A-52D. Further, the stacks need not be homogenous, but can be mixed stacks comprising sheets and panels appropriately interspersed for more efficient assembly; i.e., a stack may include both foam panels and metal sheets. In addition, the sheets and/or panels in a stack may have different sizes, and a stack may contain two or more adjacent sheets and/or stacks overlying or underlying a single sheet and/or panel, depending upon the dimensions of the sheets and/or panels and the sequence of fabrication.

As directed, turntables 52A-52D are rotated to bring sheets and panels to their respective access positions. In the manufacturing sequence described below, each turntable is rotated counterclockwise ninety (90°) degrees, as sheets and/or panels are removed from it, to bring into the access position the next appropriate sheets and/or panels. The rotation of the turntables 52A-52D can be manual, or power-driven, and in the latter case can be conducted using an appropriately-programmed computer controller, which can also control the operation of robotic assemblers 54A-54D and spray gantry 55.

For exemplary purposes, the sequence for fabricating two wall components 200, specifically wall component 200P, is described in connection with FIGS. 23A-23J. However, it should be understood that the fabrication sequence described below applies equally to the fabrication of floor components 300 and roof components 400, and to the fabrication of partitioned portions thereof. For the illustrated wall components 200, those sheets and panels in which there will be desired apertures, such as door apertures 202 and window apertures 204, are pre-cut, where appropriate, with the desired apertures, and then placed on the turntables 52B and 52D, which are located on a first side of conveyor table 50. The sheets and panels of this wall component 200 in which there will not be formed any such desired apertures are correspondingly placed on the turntables 52A and 52C, which are located on the second side of conveyor table 50. As an alternative, the formation of any door and window apertures 202, 204 can be deferred until after the fabrication steps described herein.

In general, the manufacturing sequence comprises placing on conveyor table 50 the metal sheets 206 forming the sheet metal layer 205 of the first structural layer 210, followed by the foam panels 214 of foam panel layer 213, the metal sheets 217 forming the sheet metal layer 216 of second structural layer 215, and lastly the building panels 219 of protective layer 218, in that order. In the two exemplary wall components 200 shown being fabricated in FIGS. 23A-23J, each of the layers of the wall component 200 (first structural layer 210, foam panel layer 213, second structural layer 215 and protective layer 218) is made from five sheets or panels. Accordingly, first structural layer 210 is made from five metal sheets 206 (consecutively denominated 206-1 to 206-5) that are positioned on conveyor table 50 adjacent each other; foam panel layer 213 is made from five foam panels 214 (consecutively denominated 214-1 to 214-5) that are positioned on conveyor table 50 adjacent each other; second structural layer 215 is made from five metal sheets 217 (consecutively denominated 217-1 to 217-5) that are positioned on conveyor table 50 adjacent each other; and protective layer 218 is made from five building panels 219 (consecutively denominated 219-1 to 219-5) that are positioned on conveyor table 50 adjacent each other.

For the exemplary wall components 200 fabricated in the manner shown in FIGS. 23A-23J, even-numbered sheets and panels (e.g., 206-2, 206-4, 214-2, 214-4, etc.) have apertures, specifically window apertures 204, and odd-numbered sheets and panels (e.g., 206-1, 206-3, 214-1, 214-3, etc.) do not have any such apertures. Although for ease of understanding the assembly sequence, the sheets and panels in FIGS. 22 and 23 are depicted as the same size, with one placed directly upon the other, the sheets and panels can be sized and/or placed so that the seams between adjacent sheets or panels are offset from the seams of overlying or underlying sheets or panels, so as to yield an overlapping relationship between the sheets and panels of different layers, with the goal of increasing the strength of the enclosure components 155 being fabricated, in this case wall components 200.

B. Sheet/Panel Design for Manufacturing

For enclosure components 155 having the construction disclosed in reference to FIG. 7, the sheets forming each of first structural layer 210 and second structural layer 215 can be entirely flat and juxtaposed in a simple abutting relationship, as shown in FIGS. 23A-23J (these figures are discussed below in Section C, “Sheet/Panel Manufacturing Sequence”). Optionally, metal sheets 206 and 217 can be provided with edge structures that facilitate placement of sheets and panels during manufacture.

In this regard, FIG. 8 depicts the five metal sheets 206-1 through 206-5 comprising sheet metal layer 205 of first structural layer 210 of a wall component 200 being fabricated in facility 10. The particular wall component to be fabricated from sheets 206-1 to 206-5 shown in FIGS. 23A-23B is wall component 200P, which will be positioned at a first longitudinal edge 106 of a structure 150. For better understanding, the longitudinal direction in FIG. 8 is indicated by arrow “L”, and the vertical direction in FIG. 8 is indicated by arrow “V”. The orientation of sheets 206-1 to 206-5 relative to longitudinal floor edge 117 and longitudinal roof edge 406 is additionally shown in the FIG. 8.

The present invention provides for two types of edge structures for the metal sheets utilized to fabricate enclosure components 155, namely exterior edge structures and interior edge structures. Both exterior and interior edge structures are described below with reference to metal sheets 206 of the sheet metal layer 205 forming first structural layer 210, although it should be understood that the exterior and interior edge structures described below are preferably also provided at comparable locations on metal sheets 217 of sheet metal layer 216 forming second structural layer 215.

An exterior edge structure for the metal sheets 206 of sheet metal layer 205 is shown in profile in FIG. 9A, and comprises an elongate planar edge portion 207 joined to metal sheet 206 by an edge bend 271. Edge portion 207 extends away from the interior face 208 of metal sheet 206 at a negative ninety degrees (−90°) angle bend (a negative angle bend is in the counter-clockwise direction in FIG. 9A), and is shown oriented upward in FIG. 8 and downward in FIG. 9A. Edge portion 207 is received in locating slots 229 provided in edge component sealing structures. An example of this is shown in FIG. 24A, which depicts the edge portion 207 of metal sheet 206 received in a locating slot 229 of an I-beam end cap 221 positioned on an exterior edge of roof portion 400 a. In FIG. 8, edge portions 207 are provided along the bottom and top exterior longitudinal edges of metal sheets 206-1 to 206-5 (the edges proximate to longitudinal floor edge 117 and longitudinal roof edge 406 respectively). In addition, edge portions 207 are shown in FIG. 8 as provided along the exterior vertical edges of metal sheets 206-1 and 206-5. It should also be understood that edge portions 207 can be provided at comparable locations along exterior edges of the five metal sheets 217-1 through 217-5, and in general along comparable exterior edges of any metal sheets of each other enclosure component 155 of multi-layered, laminate design in accordance with FIG. 7. Thus for example FIG. 24A also depicts the edge portion 207 of metal sheet 217 of roof portion 400 a received in a locating slot 229 of an I-beam end cap 221 positioned on an exterior edge of roof portion 400 a.

Interior edge structures for the metal sheets 206 of sheet metal layer 205 are shown in profile in FIG. 9B and 9C. There are two types of interior edge structures, an insertion section and a receiver section. For any two adjacent interior edges of metal sheets 206, a first interior edge can be provided with an insertion section of a specific design and the second interior edge can be provided with a receiver section of a specific design paired to receive the insertion section of the first interior edge. When so paired, the interior edge structures are the interface between the interior edges of two adjacent metal sheets 206, and accordingly, such paired interior edge structures are generically referenced in this disclosure as an interior edge interface 290.

FIG. 9B shows in profile a first embodiment of an interior edge interface 290, denominated 290-1, with reference to the adjacent edges of metal sheets 206-1 and 206-2. It should however be understood that interior edge interface 290-1 can also be provided at the adjacent edges of metal sheets 206-2 and 206-3, 206-3 and 206-4, and 206-4 and 206-5, as well as at comparable adjacent edges of metal sheets 217-1 and 217-2, 217-2 and 217-3, 217-3 and 217-4, and 217-4 and 217-5 and comparable adjacent edges of metal sheets of each other enclosure component 155 of laminate design in accordance with FIG. 7. Interior edge interface 290-1 comprises a receiver section 272 and an insertion section 282, as described further below.

In particular, receiver section 272 of interior edge interface 290-1 comprises a planar elongate first receiver region 273, a planar elongate second receiver region 274 and a planar elongate third receiver region 275. First receiver region 273 is shown joined in FIG. 9B to metal sheet 206-1 by an elongate edge bend 271. In FIG. 9B, edge bend 271 is a positive ninety degree (+90°) angle bend (a positive angle bend is in the clockwise direction in FIGS. 9A through 9C), so that first receiver region 273 extends away from the interior face 208 of metal sheet 206-1 in a perpendicular direction.

The portion of first receiver region 273 of interior edge interface 290-1 which is distal from edge bend 271 is joined by an elongate first bend 276 to a second receiver region 274. First bend 276 is at least a negative one hundred thirty five degree (−135°) obtuse angle bend, such as a negative one hundred eighty degree (−180°) angle bend, so that second receiver region 274 extends toward the interior face 208 of metal sheet 206-1, such as in a perpendicular direction. (In this description of edge interfaces, a linear or planar feature “extends toward” another linear or planar feature, or “extends away” from another linear or planar feature, if in the event that the two features were extended to intersect, the angle of intersection would be in the range of from greater than forty five degrees (45°) up to and including ninety degrees (90°), the perpendicular direction.)

The portion of second receiver region 274 of interior edge interface 290-1, which is distal from first bend 276, is joined by an elongate second bend 277 to third receiver region 275. Second bend 277 is at least a negative one hundred thirty five degree (−135°) bend, such as a negative a one hundred eighty degree (−180°) angle bend, such that third insertion region 275 extends away from the interior face 208 of metal sheet 206-1, such as in a perpendicular direction. The portion of third insertion region distal from second bend 277 terminates at a free edge 279. The width of first insertion region 273 (the vertical direction in FIG. 9B) is larger than the width of second insertion region 274, for example being approximately twice the width, and the width of third receiver region 275 is smaller than the width of second receiver region 274, such as to define a gap between free edge 279 and first bend 276.

FIG. 9B additionally shows first insertion section 282 of interior edge interface 290-1. That first insertion region 282 comprises a planar elongate first insertion region 283, a planar elongate second insertion region 284 and optionally a planar elongate third insertion region 285. First insertion region 283 is joined to metal sheet 206-2 by an elongate edge bend 271. Edge bend 271 at this junction is a negative ninety degree (−90°) angle bend, so that first insertion region 283 extends away from the interior face 208 of metal sheet 206 in a perpendicular direction. The portion of first insertion region 283 distal from edge bend 271 is joined by an elongate first bend 286 to second insertion region 284. First bend 286 is at least a negative one hundred thirty five degree (−135°) obtuse angle bend, such as a negative one hundred eighty degree (−180°) angle bend, so that second insertion region 284 extends toward the interior face 208 of metal sheet 206-2, such as in a perpendicular direction.

The portion of second insertion region 284 of interior edge interface 290-1, which is distal from first bend 286, is optionally joined by an elongate second bend 287 to third insertion region 285. Second bend 287 is at least a negative forty five degree (−45°) angle bend, such as a negative ninety degree (−90°) angle bend, such that optional third insertion region 285 does not extend toward the interior face 208 of metal sheet 206-2, but rather such that optional third insertion region 285 extends away from second insertion region 284 toward first insertion region 283. The portion of optional third insertion region 285 distal from second bend 287 terminates at a free edge 279.

In the embodiment of interior edge interface 290-1 shown in FIG. 9B, the length of first insertion region 283 (the vertical direction in FIG. 9B) is larger than the length of second insertion region 284, and the vertical distance between the bottom of first bend 286 and free edge 279 of third insertion region 285 should permit second and third insertion regions 284, 285 to be press-fit into the gap between free edge 279 and first bend 276 of receiver section 272. In this regard, the curvature of first bend 276 should be sufficient to permit insertion of second and third insertion regions 284, 285 into the gap between free edge 279 and first bend 276 of receiver section 272. To facilitate a smooth transition between metal sheet 206-1 and 206-2 when utilizing interior edge interface 290-1, the width of first insertion region 283 (the horizontal direction in FIG. 9B) should be equal to the width of first receiver region 273, or approximately so.

In the event that optional third insertion region 285 of interior edge interface 290-1 is not utilized, then second bend 287 terminates at free edge 279. As in the case where a third insertion region is used, second bend 287 at the location of free edge 279 is at least a negative forty five degree (−45°) angle bend, such as a negative ninety degree (−90°) angle bend. The bend angle of second bend 287 should be such that a line tangent to second bend 287 at free edge 279 does not extend toward the interior face 208 of metal sheet 206, but rather extends toward first insertion region 283. In this alternative, the vertical distance between the bottom of first bend 286 and free edge 279 of second bend 287 should permit second insertion region 284 and second bend 287 to be press-fit into the gap between free edge 279 and first bend 276 of receiver section 272.

FIG. 9C shows in profile a second embodiment of an interior edge interface 290, denominated 290-2, with reference to the adjacent edges of metal sheets 206-1 and 206-2. It should however be understood that interior edge interface 290-2 can also be provided at the adjacent edges of metal sheets 206-2 and 206-3, 206-3 and 206-4, and 206-4 and 206-5, as well as at comparable adjacent edges of metal sheets 217-1 and 217-2, 217-2 and 217-3, 217-3 and 217-4, and 217-4 and 217-5 and comparable adjacent edges of metal sheets of each other enclosure component 155 of laminate design in accordance with FIG. 7. Interior edge interface 290-2 comprises a receiver section 281 and an insertion section 291, as described further below.

In particular, receiver section 281 of interior edge interface 290-2 comprises a planar elongate first receiver region 273 and a planar elongate second receiver region 274. First receiver region 273 is shown joined in FIG. 9C to metal sheet 206-1 by an elongate edge bend 271. In FIG. 9C, edge bend 271 is a positive ninety degree (+90°) angle bend, so that first receiver region 273 extends away from the interior face 208 of metal sheet 206-1 in a perpendicular direction.

The portion of first receiver region 273 of interior edge interface 290-2, which is distal from edge bend 271, is joined by an elongate first bend 276 to second receiver region 274. First bend 276 is at least a negative one hundred thirty five degree (−135°) obtuse angle bend, such as a negative one hundred eighty degree (−180°) angle bend, so that second receiver region 274 extends toward the interior face 208 of metal sheet 206-1, such as in a perpendicular direction. The portion of second receiver region 274 distal from first bend 276 terminates at a free edge 279.

FIG. 9C additionally shows first insertion section 291 of interior edge interface 290-2. That first insertion section 291 comprises a planar elongate first insertion region 283 and a planar elongate second insertion region 284. First insertion region 283 is joined to metal sheet 206-2 by an elongate edge bend 271. In FIG. 9C, edge bend 271 is a negative ninety degree (−90°) angle bend, so that first insertion region 283 extends away from the interior face 208 of metal sheet 206 in a perpendicular direction.

The portion of first insertion region 283 of interior edge interface 290-2, which is distal from edge bend 271, is joined by an elongate first bend 286 to second insertion region 284. First bend 286 is at least a negative one hundred thirty five degree (−135°) bend, such as a one hundred eighty degree (180°) angle bend, such that second insertion region 284 extends toward the interior face 208 of metal sheet 206, such as in a perpendicular direction. The portion of second insertion region 284 of interior edge interface 290-2, which is distal from first bend 286 terminates at a free edge 279.

In interior edge interface 290-2 shown in FIG. 9C, the length of first insertion region 283 (the vertical direction in FIG. 9C) is shown as larger than the length of second insertion region 284; for example, first insertion region 283 can be at least double the length of second insertion region 284. Also, the length of first receiver region 273 is shown as larger than the length of second receiver region 274; for example, first receiver region 273 can be at least double the length of second receiver region 274. In this regard, the curvature of first bend 276 should be such as to permit insertion of first and second insertion regions 283, 284 between first and second receiver regions 273, 274. To facilitate a smooth transition between metal sheet 206-1 and 206-2 when utilizing interior edge interface 290-2, the width of first insertion region 283 should be equal to the width of first receiver region 273, or approximately so.

C. Sheet/Panel Manufacturing Sequence

To fabricate an enclosure component 155 of laminate design in accordance with FIG. 7 (as exemplified by the wall components 200, specifically wall components 200P, prepared in FIGS. 23A-23J), Table 1 identifies the turntable on which is located each of the required sheets and panels, as well as the sequence in which they are moved, either by manufacturing personnel or by robotic assemblers 54A and 54B, from the turntables 52A and 52B to conveyor table 50. A like sequence can be followed for all enclosure components 155—wall components 200, floor components 300 and roof components 400—used in structure 150 depicted in FIG. 1.

TABLE 1 Sheet/Panel Source and Movement Sequence Turntable 52A Turntable 52B metal sheet 206-1 (1^(st) structural layer 210) metal sheet 206-2 (1^(st) structural layer 210) Rotate turntable ninety degrees (90°) metal sheet 206-3 (1^(st) structural layer 210) metal sheet 206-4 (1^(st) structural layer 210) metal sheet 206-5 (1^(st) structural layer 210) Rotate turntable ninety degrees (90°) foam panel 214-1 (foam panel layer 213) foam panel 214-2 (foam panel layer 213) Rotate turntable ninety degrees (90°) Rotate turntable ninety degrees (90°) foam panel 214-3 (foam panel layer 213) foam panel 214-4 (foam panel layer 213) Rotate turntable ninety degrees (90°) foam panel 214-5 (foam panel layer 213) metal sheet 217-1 (2^(nd) structural layer 215) metal sheet 217-2 (2^(nd) structural layer 215) metal sheet 217-3 (2^(nd) structural layer 215) Rotate turntable ninety degrees (90°) Rotate turntable ninety degrees (90°) metal sheet 217-4 (2^(nd) structural layer 215) metal sheet 217-5 (2^(nd) structural layer 215) Rotate turntable ninety degrees (90°) building panel 219-1 (protective layer 218) building panel 219-2 (protective layer 218) Rotate turntable ninety degrees (90°) building panel 219-3 (protective layer 218) building panel 219-4 (protective layer 218) building panel 219-5 (protective layer 218)

Table 1 also applies to the wall assembly 200 fabricated from the sheets and panels positioned on turntables 52C and 52D; i.e., the column in Table 1 for turntable 52A also applies to turntable 52C, and the column in Table 1 for turntable 52B also applies to turntable 52D.

Step 1: First Structural Layer Formation. FIG. 23A depicts robotic assemblers 54A-54D moving metal sheets 206 from their access positions on turntables 52A-52D to pre-selected locations in assembly area 56 (shown in FIG. 22) on conveyor table 50. In accordance with the movement sequence described in Table 1, robotic assemblers 54A-54D move metal sheets 206-1 through 206-5 in sequence to conveyor table 50 until all sheets forming first structural layer 210 of the two exemplary wall components 200 have been appropriately placed in assembly area 56 on conveyor table 50.

If exterior or interior edge structures are provided on metal sheets 206-1 to 206-5, then those structures should be oriented to face upward when placed on conveyor table 50, as shown in FIG. 8, and the receiving section of each metal sheet 206-1 through 206-4 should be oriented to receive the insertion section of the adjacent sheet 206-2 through 206-5 respectively. The use of interior edge interfaces 290 facilitates the accurate placement of the metal sheets 206-1 through 206-5 adjacent to each other. At the particular point in manufacturing shown in FIG. 23A, robotic assembler 54A has already removed metal sheet 206-1 from its access position on turntable 52A and placed it at a preselected location in assembly area 56 on conveyor table 50, and turntable 52A has been rotated counterclockwise ninety degrees (90°) to bring into the access position the next sheet or panel for placement onto conveyor table 50, in this case metal sheet 206-3. Likewise at the particular point in manufacturing shown in FIG. 23A, robotic assembler 54B has already removed a metal sheet 206-2 from its access position on turntable 52B and placed it at a preselected location in assembly area 56 on conveyor table 50, adjacent metal sheet 206-1.

Step 2: First Adhesive Application. FIG. 23B depicts all metal sheets 206-1 to 206-5 forming first structural layer 210 of the exemplary two wall components 200 properly placed in assembly area 56 on conveyor table 50, after having been moved there by robotic assemblers 54A-54D. The exposed faces of sheets 206 are then coated with adhesive. This step is performed by spray gantry 55, which moves over the exposed faces of sheets 206, in the direction “L”, as indicated by the arrow in FIG. 23C, from a position proximate press table 51 to a position distal from press table 51, while spraying adhesive on the exposed faces so as to coat substantially the entirety of the exposed faces. Optionally, gantry 55 can remain distal from press table 51 after completing the adhesive spray, as shown in FIG. 23D, until utilized in a subsequent manufacturing step.

Step 3: Foam Panel Layer Formation. FIG. 23D depicts robotic assemblers 54A-54D moving foam panels 214-1 and 214-2 from their access positions on turntables 52A-52D to preselected locations in assembly area 56 (shown in FIG. 22), overlying the adhesive-coated sheets 206 positioned on conveyor table 50. In like manner, and in accordance with the movement sequence described in Table 1, further foam panels 214 are moved in a preselected sequence to conveyor table 50 until all panels forming foam panel layer 213 of the two exemplary wall components 200 are in their appropriate position on conveyor table 50; thus FIG. 23E depicts the final foam panel 214-5 forming foam panel layers 210 of the exemplary two wall components 200 being placed in assembly area 56 on conveyor table 50 by robotic assemblers 54A and 54C.

Foam panels 214-1 through 214-5 preferably are pre-cut with channels 209 at appropriate locations so as to receive any interior edge structures on the metal sheets 206-1 to 206-5, which extend beyond the plane of metal sheets 206-1 to 206-5, so that the foam panels lie flush on metal sheets 206-1 to 206-5. Foam panels 214-1 through 214-5 preferably are also pre-cut with channels 209 at appropriate locations so as to receive any interior edge structures on metal sheets 217-1 to 217-5, which are to be positioned above the foam panels in Step 5 below, so that metal sheets 217-1 to 217-5 will lie flush on the foam panels. Comparable channels 209 preferably are pre-cut in the foam panels utilized for each other enclosure component 155 of laminate design in accordance with FIG. 7 to accommodate such interior edge structures as may be utilized between the interior edges of adjacent metal sheets. FIG. 24B is an example of an interior edge interface 290-2 between two adjacent representative metal sheets, denominated 206-x and 206-y, as it is received in a channel 209.

Following placement of foam panels 214-1 through 214-5 on conveyor table 50 to form foam panel layer 213, any exterior edge reinforcement and sealing structures to be utilized can be positioned in place. For example, wall end caps 246 of suitable length can be positioned and fastened to floor plate 220, ceiling plate 240 and end pieces 270, and these subassemblies can then be placed on conveyor table 50, with their locating slots 229 receiving the edge portions 207 located along the longitudinal and vertical edges of metal sheets 206-1 and 206-5.

Step 4: Second Adhesive Application. Following Step 3, the exposed faces of foam panels 214 are coated with adhesive. This step is performed by spray gantry 55, in a manner similar to the depiction in FIG. 23C. In particular, spray gantry 55 moves over the exposed faces of foam panels 214, while spraying adhesive on the exposed faces so as to coat substantially the entirety of the exposed faces. In the embodiment depicted in FIGS. 23A-23J, spray gantry 55 applies adhesive to foam panels 214 by moving from a position distal from press table 51 to a position proximate press table 51.

Step 5: Second Structural Layer Formation. FIG. 23F depicts robotic assemblers 54A-54D moving metal sheets 217-1 and 217-2 from their access positions on turntables 52A-52D to preselected locations in assembly area 56 (shown in FIG. 22), overlying the adhesive-coated foam panels 24 previously formed on conveyor table 50. In like manner, and in accordance with the movement sequence described in Table 1, further sheets 217 are moved in a preselected sequence to conveyor table 50 until all sheets forming second structural layer 215 of the two exemplary wall components 200 are in their appropriate positions on conveyor table 50.

When placed upon the adhesive-coated foam panels 214 positioned on conveyor table 50, any and all exterior and interior edge structures on metal sheets 217-1 to 217-5 should face downward, not upward as shown in FIG. 8, and the receiving section of each metal sheet 217-1 through 217-4 should be oriented to receive the insertion section of the adjacent sheet 217-2 through 217-5 respectively. The use of interior edge interfaces 290 facilitates the accurate placement of the metal sheets 217-1 through 217-5 adjacent to each other. Metal sheets 217-1 through 217-5, when placed upon the adhesive-coated foam panels 214, should be positioned so that their edge portions 207 are received in the locating slots 229 of the wall end caps 246 previously secured in place, and as indicated above, should be positioned so that any and all interior edge structures on metal sheets 217-1 to 217-5 are received in appropriately located, pre-cut channels 209 in foam panels 214-1 through 214-5, so that sheet metal layer 216 lies flush on foam panel layer 213.

Step 6: Third Adhesive Application. FIG. 23G depicts the final metal sheet 217-5 forming second structural layer 215 of the exemplary two wall components 200 being placed in assembly area 56 on conveyor table 50 by robotic assembler 54A. After that placement, the exposed faces of metal sheets 217 are coated with adhesive. This step is performed by spray gantry 55, in a manner similar to the depiction in FIG. 23C. In particular, spray gantry 55 moves over the exposed faces of metal panels 217, while spraying adhesive on the exposed faces so as to coat substantially the entirety of the exposed faces. In the embodiment depicted in FIGS. 23A-23J, spray gantry 55 applies adhesive to metal sheets 217 by moving from a position proximate press table 51 to a position distal from press table 51. Optionally, gantry 55 can remain distal to press table 51 after completing the adhesive spray, as shown in FIG. 23F, until utilized in a subsequent manufacturing step, or can be returned to a position proximate press table 51.

Step 7: Protective Layer Formation. FIG. 23H depicts robotic assemblers 54A-54D moving building panels 219-1 and 219-2 from their access positions on turntables 52A-52D to preselected locations in assembly area 56 (shown in FIG. 5), overlying the adhesive-coated metal sheets 217 previously formed on conveyor table 50. In like manner, and in accordance with the movement sequence described in Table 1, further building panels 219 are moved in a preselected sequence to conveyor table 50 until all sheets forming protective layer 218 of the two exemplary wall components 200 are in their appropriate positions on conveyor table 50.

During this step 7, a wall end interlock B 263 of suitable length can be positioned on the interior edge of the wall component 200 (specifically wall component 200P), abutting protective layer 218 and proximate what will be the first transverse edge 108 of structure 150, and a wall end interlock B 263 of suitable length can be positioned on the interior edge of the wall component 200 (specifically wall component 200P), abutting protective layer 218 and proximate what will be the second transverse edge 110 of structure 150.

Step 8: Laminate Press. After all building panels 219 forming protective layer 218 of the two exemplary wall components 200 are in their assembly position on conveyor table 50, each work piece is moved from conveyor table 50 into press table 51, as exemplified by FIG. 23J. Within press table 51, the work pieces are sandwiched between flexible sheets and a vacuum is applied between the sheets, which causes the panels and sheets of the work piece to be pressed together under atmospheric pressure to finish the laminate structure. In the embodiment shown, the press table is sized to accommodate both work pieces at the same time.

After the laminate press step (Step 8), the wall components 200 are removed from press table 51 and then subject to any desired finishing steps to complete the wall components 200.

Optionally, in appropriate situations certain of the foregoing manufacturing sequence steps can be initiated prior to completion of the previous manufacturing sequence step, such that the manufacturing steps are conducted at least in part in an overlapping manner For example, the foam panel layer formation performed in step 3 can be initiated prior to completion of the adhesive application performed in step 2. Thus as can be seen in FIG. 23C, robotic assemblers 54A-54D are depicted as already starting to engage the foam panels 214 needed for foam panel layer formation, while spray gantry 55 is still spraying adhesive on the exposed faces of sheets 206. Overlapping the manufacturing sequence steps in this manner advantageously reduces overall manufacturing time.

Enclosure Component Relationships and Assembly for Transport

For ease of transport and maximum design flexibility, it is preferred that there be a specific dimensional relationship among enclosure components 155.

FIG. 2 shows a top schematic view of structure 150 shown in FIG. 1, and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components 155. The basic length used for dimensioning is indicated as “E” in FIG. 2; the orthogonal grid overlaid in FIG. 2 is 8E long and 8E wide; notably, the entire structure 150, including perimeter boards 310, preferably is bounded by this 8E by 8E orthogonal grid.

Roof portions 400 a, 400 b and 400 c each can be identically dimensioned in the transverse direction. Alternatively, referring to FIG. 3, roof portion 400 c (which is stacked upon roof portions 400 a and 400 b when roof portions 400 b, 400 c are fully folded) can be dimensioned to be larger than either of roof portion 400 a and roof portion 400 b in the transverse direction for example, by ten to fifteen percent, or by at least the aggregate thickness of roof components 400 a and 400 b. This transverse direction dimensional increase is to reduce the chances of binding during the unfolding of roof portions 400 b, 400 c. In addition, as described in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, friction-reducing components can be used to facilitate unfolding roof component 400, such as by positioning a first wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s-2 as roof portion 400 c is deployed, and by positioning a second similar wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s-4 as roof portion 400 c is deployed. In such a case, roof portion 400 c can be dimensioned larger than either of roof portions 400 a and 400 b in the transverse direction by at least the aggregate thickness of roof components 400 a and 400 b, less the length of the first or second wheel caster.

In FIG. 2, the four wall components 200 are each approximately 8E long, and each of roof portions 400 a and 400 b is approximately 8E long and 2.5E wide. Roof portion 400 c is approximately 8E long and 2.9E wide. In FIGS. 2 and 3, each of floor components 300 a and 300 b is 8H long; whereas floor component 300 a is just over 3E wide and floor component 300 b is just under 5E wide.

The shipping module 100 shown edge-on in FIG. 3 includes a fixed space portion 102 defined by roof component 400 a, floor component 300 a, wall component 200R, wall portion 200 s-1 and wall portion 200 s-3. As shown in FIG. 2, second wall portion 200 s-2 is folded inward and positioned generally against fixed space portion 102, and fourth wall portion 200 s-4 is folded inward and positioned generally against second wall portion 200 s-2 (wall portions 200 s-2 and 200 s-4 are respectively identified in FIG. 2 as portions 200 s-2 f and 200 s-4 f when so folded and positioned). The three roof components 400 a, 400 b and 400 c are shown unfolded in FIG. 1 and shown folded (stacked) in FIG. 3, with roof component 400 b stacked on top of roof component 400 a, and roof component 400 c stacked on top of the roof component 400 b. Wall component 200P, shown in FIGS. 2 and 3, is pivotally secured to floor portion 300 b at the location of axis 105, and is vertically positioned against the outside of wall portions 200 s-2 and 200 s-4. In turn, floor portion 300 b is vertically positioned proximate fixed space portion 102, with wall component 200P pending from floor portion 300 b between floor portion 300 b and wall portions 200 s-2 and 200 s-4.

Sizing the enclosure components 155 of structure 150 according to the dimensional relationships disclosed above yields a compact shipping module 100, as can be seen from the figures. Thus shipping module 100 depicted in FIG. 3, when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2) of approximately 28.625 inches (72.7 cm), and when its components are stacked and positioned as shown in FIG. 3, has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.

It is preferred that the fixed space portion 102 be in a relatively finished state prior to positioning (folding) together all of the other wall, roof and floor portions as described above. In the embodiment shown in FIGS. 1 and 2, wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components 155 being pre-wired, and fixed space portion 102 is fitted during manufacture with all mechanical and other functionality that structure 150 will require, such as kitchens, bathrooms, closets and other interior partitions, storage areas, corridors, etc. Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of shipping module 100.

Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film 177 during fabrication and prior to forming the shipping module 100. Alternatively or in addition, the entire shipping module 100 can be sheathed in a protective film. Such protective films can remain in place until after the shipping module 100 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.

Shipping Module Transport

The shipping module 100 is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of which are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2D thereof. As an alternative transport means, shipping module 100 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship.

Structure Deployment and Finishing

At the building site, shipping module 100 is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns. This can be accomplished by using a crane, either to lift shipping module 100 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 100, then moving the transport means from the desired location, and then lowering shipping module 100 to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 100 at the desired location are disclosed in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” having the same inventors as this disclosure and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at paragraphs 126-128 and in connection with FIGS. 11A and 11B thereof.

Following positioning of shipping module 100 at the building site, the appropriate portions of wall, floor and roof components 200, 300 and 400 are “unfolded” (i.e., deployed) to yield structure 150. Unfolding occurs in the following sequence: (1) floor portion 300 b is pivotally rotated about horizontal axis 305 (shown in FIGS. 3 and 4) to an unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105 (shown in FIG. 3 behind perimeter board 312) to an unfolded position, (3) wall portions 200 s-2 and 200 s-4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2) respectively to unfolded positions, and (4) roof portions 400 b and 400 c are pivotally rotated about horizontal axes 405 a and 405 b (shown in FIGS. 3 and 4) respectively to unfolded positions.

A mobile crane can be used to assist in the deployment of certain of the enclosure components 155, specifically roof portions 400 b and 400 c, floor portion 300 b, as well as the wall component 200P pivotally secured to floor portion 300 b. Alternatively, particularly suitable equipment and techniques for facilitating the deployment of enclosure components 155 are disclosed in U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020. The contents of that U.S. Nonprovisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” having the same inventors as this disclosure and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at paragraphs 132-145 and depicted in FIGS. 12A-14B thereof.

After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1. Perimeter board 312 and roof skirt board 280 provide structures for securing wall, floor and roof components in their deployed positions. If any temporary hinge structures have been utilized, then these temporary hinge structures can be removed if desired and the enclosure components 155 can be secured together. During or after unfolding and securing of the enclosure components 155, any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to complete structure 150, as relevant here.

The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims. 

What is claimed is:
 1. An enclosure component for a building structure comprising: a first structural layer including a rectangular first metal sheet having an interior sheet face, an exterior sheet face and a first exterior sheet edge having an elongate edge portion bent to extend away from the interior sheet face; a planar foam panel layer having a first face, an opposed second face and a first exterior panel edge, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet; and a planar elongate first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer, the first edge seal including an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.
 2. The enclosure component of claim 1, wherein the first exterior seal face of the first edge seal defines an elongate slot.
 3. The enclosure component of claim 2, wherein the elongate slot is a seal slot in which is positioned an elongate resilient first compression seal adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal.
 4. The enclosure component of claim 2, wherein the elongate slot is an interlock slot positioned distal from the first and second edges, which is adapted to receive an interlock key defined in a second exterior seal face of a second edge seal.
 5. The enclosure component of claim 4, wherein the first exterior seal face of the first edge seal defines a first seal slot positioned between the interlock slot and the first edge and a second seal slot positioned between the interlock slot and the second edge, and the enclosure component further comprises an elongate resilient first compression seal positioned in the first seal slot and an elongate resilient second compression seal positioned in the second seal slot, the first and second compression seals adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal.
 6. The enclosure component of claim 1, further comprising an interlock key on the first exterior seal face of the first edge seal, which is adapted to be received in an interlock slot defined in a second exterior seal face of a second edge seal.
 7. The enclosure component of claim 5, wherein the first exterior seal face of the first edge seal defines a third seal slot positioned between the interlock slot and the first seal slot, and the enclosure component further comprises an elongate resilient third compression seal positioned in the third seal slot and adapted to be positioned in pressing contact with the second exterior seal face of the second edge seal.
 8. The enclosure component of claim 1, further comprising a planar protective layer having a thickness and bonded to the exterior sheet face of the first metal sheet, and wherein the first locating slot is defined by a first portion of the first edge seal proximate to its first edge and abutting the first interior seal face and a second portion of the first edge seal proximate its first edge and abutting the first exterior seal face, with the first portion terminated an inset distance from the first edge that is equal to the thickness of the protective layer.
 9. The enclosure component of claim 1, further comprising a second structural layer including a rectangular second metal sheet having an interior sheet face, an exterior sheet face and a second exterior sheet edge; the second face of the foam panel layer being bonded to the interior sheet face of the second metal sheet; the second exterior sheet edge of the second metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the second metal sheet; and the first edge seal including an elongate second locating slot, defined on the second edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior sheet edge of the second metal sheet.
 10. The enclosure component of claim 1, further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet.
 11. The enclosure component of claim 9, further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet.
 12. The enclosure component of claim 1, wherein: the first metal sheet has a second exterior sheet edge adjacent its first exterior sheet edge, the foam panel layer has a second exterior panel edge adjacent its first exterior panel edge, the second exterior panel edge has an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet, and the enclosure component further comprises: a planar elongate second edge seal having a second interior seal face, an opposed second exterior seal face, a third edge and an opposed fourth edge, the second interior seal face positioned proximate to the second exterior panel edge of the foam panel layer, the second edge seal including an elongate second locating slot, defined on the third edge between the second interior seal face and the second exterior seal face, and in which is positioned the elongate edge portion of the second exterior sheet edge of the first metal sheet.
 13. The enclosure component of claim 12, wherein: the first metal sheet has a third exterior sheet edge adjacent its first exterior sheet edge and opposing its second exterior sheet edge, the foam panel layer has a third exterior panel edge adjacent its first exterior panel edge and opposing its second exterior panel edge, the third exterior sheet edge has an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet, and the enclosure component further comprises: a planar elongate third edge seal having a third interior seal face, an opposed third exterior seal face, a fifth edge and an opposed sixth edge, the third interior seal face positioned proximate to the third exterior panel edge of the foam panel layer, the third edge seal including an elongate third locating slot, defined on the fifth edge between the third interior seal face and the third exterior seal face, and in which is positioned the elongate edge portion of the third exterior edge of the third metal sheet.
 14. The enclosure component of claim 1, wherein the first edge seal is foamed polyvinyl chloride.
 15. The enclosure component of claim 12, wherein the first and second edge seals are foamed polyvinyl chloride.
 16. The enclosure component of claim 13, wherein the first, second and third edge seals are foamed polyvinyl chloride.
 17. The enclosure component of claim 1, further comprising a first edge reinforcement member positioned between the first exterior panel edge of the foam panel layer and the first interior seal face of the first edge seal.
 18. The enclosure component of claim 12, further comprising a second edge reinforcement member positioned between the second exterior panel edge of the foam panel layer and the second interior seal face of the first edge seal.
 19. The enclosure component of claim 13, further comprising a third edge reinforcement member positioned between the third exterior panel edge of the foam panel layer and the third interior seal face of the first edge seal.
 20. An enclosure component for a building structure comprising: a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet; with the first metal sheet having an interior sheet face, a first exterior sheet edge and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior sheet edge of the first metal sheet; the first interior sheet edge of the first metal sheet including a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet; the second interior edge of the second metal sheet including an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the first metal sheet; the insertion section of the second metal sheet positioned within the receiver section of the second metal sheet; the first exterior edge of the first metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the first metal sheet; a planar foam panel layer having a first face, an opposed second face, and an exterior panel edge, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, with the first face of the foam panel layer defining a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section; and a first edge seal having a first interior seal face, an opposed first exterior seal face, a first edge and an opposed second edge, the first interior seal face positioned proximate to the exterior panel edge of the foam panel layer, the first edge seal including an elongate first locating slot, defined on the first edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the exterior edge of the first metal sheet.
 21. The enclosure component of claim 20, wherein: the receiver section further comprises a planar elongate third receiver region joined by a second receiver bend to the second receiver region distal from the first receiver bend to extend away from the interior sheet face of the first metal sheet, with the second receiver region distal from the second receiver bend terminating at a free edge; and the insertion section further comprises a second insertion bend joined to the first insertion region distal from the first insertion bend.
 22. The enclosure component of claim 21, wherein the second insertion bend terminates at a free edge having a tangent line extending toward the first insertion region.
 23. The enclosure component of claim 21, further comprising a third insertion region joined to the second insertion bend with the third insertion region extending toward the first insertion region.
 24. The enclosure component of claim 20, wherein the second receiver region distal from the first receiver bend terminates at a free edge, and the second insertion region distal from the second insertion bend terminates at a free edge.
 25. The enclosure component of claim 20, further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet and to the exterior sheet face of the second metal sheet.
 26. The enclosure component of claim 20, wherein the first exterior seal face of the first edge seal defines an elongate slot.
 27. The enclosure component of claim 26, wherein the elongate slot is a seal slot in which is positioned an elongate resilient first compression seal that is adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal.
 28. The enclosure component of claim 26, wherein the elongate slot is an interlock slot positioned distal from the first and second edges which is adapted to receive an interlock key defined in a second exterior seal face of a second edge seal.
 29. The enclosure component of claim 28, wherein the first edge seal defines a first seal slot positioned between the interlock slot and the first edge and a second seal slot positioned between the interlock slot and the second edge, and the enclosure component further comprises an elongate resilient first compression seal positioned in the first seal slot and an elongate resilient second compression seal positioned in the second seal slot, the first and second compression seals adapted to be positioned in pressing contact with a second exterior seal face of a second edge seal.
 30. The enclosure component of claim 20, further comprising an interlock key on the first exterior seal face of the first edge seal which is adapted to be received in an interlock slot defined in a second exterior seal face of a second edge seal.
 31. The enclosure component of claim 29, wherein the first edge seal defines a third seal slot positioned between the interlock slot and the first seal slot, and the enclosure component further comprises an elongate resilient third compression seal positioned in the third seal slot and adapted to be positioned in pressing contact with the second exterior seal face of the second edge seal.
 32. The enclosure component of claim 20, further comprising a planar protective layer having a thickness and bonded to the exterior sheet face of the first metal sheet, and wherein the first locating slot is defined by a first portion of the first edge seal proximate to its first edge and abutting the first interior seal face and a second portion of the first edge seal proximate its first edge and abutting the first exterior seal face, and the first portion is terminated an inset distance from the first edge that is equal to the thickness of the protective layer.
 33. The enclosure component of claim 20, further comprising a second structural layer including a rectangular third metal sheet having an interior sheet face, an exterior sheet face and a second exterior sheet edge; the second face of the foam panel layer being bonded to the interior sheet face of the third metal sheet; the second exterior sheet edge of the third metal sheet including an elongate edge portion bent to extend away from the interior sheet face of the third metal sheet; and the first edge seal including an elongate second locating slot, defined on the second edge between the first interior seal face and the first exterior seal face, in which is positioned the elongate edge portion of the second exterior sheet edge of the third metal sheet.
 34. The enclosure component of claim 20, further comprising an edge reinforcement member positioned between the exterior panel edge of the foam panel layer and the first interior seal face of the first edge seal.
 35. An enclosure component for a building structure comprising: a first structural layer including a rectangular first metal sheet and a rectangular second metal sheet; with the first metal sheet having an interior sheet face and a first interior sheet edge, and the second metal sheet having an interior sheet face and a second interior sheet edge positioned adjacent the first interior edge of the first metal sheet; the first interior sheet edge of the first metal sheet including a receiver section comprising a planar elongate first receiver region bent to extend away from the interior sheet face of the first metal sheet, and a planar elongate second receiver region joined by a first receiver bend to the first receiver region to extend toward the interior sheet face of the first metal sheet, with a portion of the planar elongate second receiver region closest to the interior sheet face of the first metal sheet terminating at a free edge distal from the first receiver bend; the second interior edge of the second metal sheet including an insertion section comprising a planar elongate first insertion region bent to extend away from the interior sheet face of the second metal sheet, and a planar elongate second insertion region joined by a first insertion bend to the first insertion region to extend toward the interior sheet face of the second metal sheet, with a portion of the planar elongate second insertion region closest to the interior sheet face of the second metal sheet terminating at a free edge distal from the first insertion bend; the insertion section of the second metal sheet positioned within the receiver section of the first metal sheet; and a planar foam panel layer having a first face and an opposed second face, the first face of the foam panel layer being bonded to the interior sheet face of the first metal sheet and to the interior sheet face of the second metal sheet, with the first face of the foam panel layer including a channel in which is received the first receiver section and the first insertion section positioned in the first receiver section.
 36. The enclosure component of claim 35, wherein: the receiver section further comprises a planar elongate third receiver region joined by a second receiver bend to the second receiver region distal from the first receiver bend to extend away from the interior sheet face of the first metal sheet, with the second receiver region distal from the second receiver bend terminating at a free edge; and the insertion section further comprises a second insertion bend joined to the first insertion region distal from the first insertion bend.
 37. The enclosure component of claim 36, wherein the second insertion bend terminates at a free edge having a tangent line extending toward the first insertion region.
 38. The enclosure component of claim 36, further comprising a third insertion region joined to the second insertion bend with the third insertion region extending toward the first insertion region.
 39. The enclosure component of claim 35, wherein the second receiver region distal from the first receiver bend terminates at a free edge, and the second insertion region distal from the second insertion bend terminates at a free edge.
 40. The enclosure component of claim 35, further comprising a planar protective layer bonded to the exterior sheet face of the first metal sheet and to the exterior sheet face of the second metal sheet. 